System and method including specimen gripper

ABSTRACT

A system is disclosed. The system may include any suitable combination of a sensing gripper unit, a gripper unit with removable gripper fingers, an element or chute arrangement for separating gripper fingers from an object being gripped, and a detection system for detecting the level of objects in a container such as a waste container. The system may be used in a laboratory environment where objects such as specimen containers, caps, and tubes are manipulated.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a non-provisional application of and claims the benefit of priority of U.S. Provisional Application No. 61/790,446 filed on Mar. 15, 2013, and U.S. Provisional Application No. 61/714,656 filed on Oct. 16, 2012, each of which is herein incorporated by reference in its entirety for all purposes.

BACKGROUND

Conventional medical laboratory systems contain many segments for processing patient samples, some of which are automated and some of which require manual operation. Laboratory systems have become more efficient due to those segments which have become automated. However, there are still several components of medical laboratory systems that can be automated in order to reduce the time it takes for an analysis of a sample, the reliance on human intervention, and the space required to house such systems. A number of other improvements to conventional laboratory automation systems are also desirable to improve the speed and reliability of sample processing.

When automating sample tube manipulation processes (loading, uploading devices, such as racks, instruments, conveyors) that are normally performed by lab technicians, additional handling is required to manage unknown variations in specimen containers. Such variations may include sticky labels, various specimen container diameters and heights, different cap styles, different cap colors, etc. Such variations may result in the mishandling of specimen containers, and may result in dropping, misplacing, or breaking the specimen container. If this occurs, the processing speed and processing quality can be affected. Further, such variations may be hazardous to lab technicians, and can result in cross contamination problems.

Other problems to be addressed relate to the speed of processing in laboratory automation systems. It takes time for automated systems to automatically characterize a specimen container, e.g., a sample tube, if there are many types of specimen containers in a laboratory. It also takes time for automated systems to automatically characterize specimens inside of the specimen containers if there are many types of specimens in a laboratory. In automated specimen processing systems, the throughput and speed of processing specimens is of primary importance. Hence, there is a need for an improved automation system for efficient management of the samples.

The use of robot arms in various areas of an automated specimen processing system is known. A robotic arm unit can couple to a gripper unit for gripping specimen containers using gripper fingers. However, the gripper fingers of the gripper unit may not be easily replaceable. For example, the gripper fingers may need to be repaired due to wear or service.

In some cases, the gripper unit may need to perform different functions using special gripper fingers customized for each function. This may require frequently exchanging the gripper fingers. For example, a gripper unit may be used as a tube gripper, a recapper or a decapper in a laboratory automation system. It may be desirable to change the gripper fingers in the gripper unit in these situations.

In some cases, the entire gripper unit may need to be demounted and remounted when the gripper fingers need to be replaced or repaired. Additionally, mounting or demounting of the fingers may require tools (e.g., a screw driver) and a certain amount of time (e.g., for removal of the screws). This can lead to sample processing delays. In such cases, it is desirable to have the flexibility of quickly and easily replacing the gripper fingers without requiring tools (e.g., a screwdriver) and without the need to demount the entire gripper unit to exchange the fingers.

Also in automated specimen processing systems, waste objects such as specimen containers with expired storage times, secondary test tubes, etc. may be collected in a waste container for disposal. For example, a gripper unit attached to a robotic arm may grip waste objects from various work units in a laboratory system to dispose them in a waste container. However, in some cases, when the gripper unit releases the waste object into the waste container, the waste object may get stuck to the gripper unit and may not separate from the gripper unit. For example, there may be contamination on the outside surface of the waste object (e.g., from a prior aliquotting process) that may cause the object to stick to the gripper fingers. In another example, a label on the waste object may have come off or the glue from the label may have caused the object to be stuck to the gripper fingers during the waste disposal process. In such cases, human intervention may be required to remove the waste object from the gripper unit. This causes processing delays and requires a human being to correct the problem. Furthermore, in this process, contamination may be transported with the gripper fingers from one waste object to another, thus further increasing the likelihood of spreading the contamination.

In some cases, to minimize reliance on human intervention it may be desirable to automatically detect when the waste container is full. Level indicators for containers used in the medical laboratory systems are known. One such approach is discussed in the U.S. Pat. No. 5,918,739 titled “Full Level Indicator for Medical Disposable Container” by Bilof et al. However, one problem with this type of system is that a signal is only sent out when the waste container reaches a maximum level. Instruments upstream and downstream of the disposal container may not have time to adjust their processes if the disposal container only alerts the system when it reaches a maximum level. Instruments upstream and downstream of the disposal container may have to shut down to allow the waste container to be emptied.

Another problem to be addressed, particularly in a laboratory environment, is that there are a number of different waste items and consumables (e.g., reagent packs, pipettes, etc.) that have different dimensions and waste containers also have different dimensions. Accordingly, simple fill level detectors would have limited value, since it would be difficult to inform the system how many more items can fill the container or how many more items can be removed from the container. As noted above, this information may be useful when upstream and downstream instruments (or a human operator) need to be informed about how they should operate to minimize downtime.

One method that is used to detect a waste fill level using a waste counter in the existing Beckman Automate™ 2500 series (e.g., in an aliquotting module) is described. In this system, a maximum volume of waste, e.g. a thousand units, is hardcoded into the Automate software and represents the maximum fill level of the container. For instance, in this system, a discarded changeable tip is counted as one unit, and a discarded secondary tube is counted as five units. The waste counter indicates a fill level of the container as the container is filled with discarded objects. The current fill level may be loaded from a memory, which may be zero or a predetermined value. After discarding step, the fill level of the container (i.e., the waste counter) is incremented by one for changeable tips or five for discarded secondary tubes. After every discarding step, the fill level is checked for a maximum level by the software and the updated fill level is stored in the memory. When the fill level is more than the maximum volume of the waste (e.g. hardcoded value), the user or the operator is warned to clear the waste and reset the waste counter. The actual fill level is rest and saved into the memory.

Detecting only the maximum level of the container may be inefficient in some cases since it may result in overfilling of the container if the operator does not have sufficient time to react. Therefore, it would be desirable to get timely information so that the operator can react in time and can schedule maintenance actions accordingly.

Embodiments of the invention address these and other problems, individually and collectively.

BRIEF SUMMARY

Embodiments of the invention relate to systems and methods for handling specimen containers.

One embodiment of the invention system for use in manipulating a specimen container. The system includes a gripper unit for gripping the specimen container. The gripper unit comprises a mounting structure, a plurality of gripper fingers, a plurality of release elements respectively coupling the gripper fingers in the plurality of gripper fingers to the mounting structure, and a sensing device, wherein the sensing device is configured to produce an output. The system further includes a processor, where the processor is configured to determine a dimension or a weight of the specimen container based on the output.

Another embodiment of the invention is directed to a system. The system comprises an element comprising a tubular body comprising a central axial bore running the length of said body with a first open end and a second open end, the first end including two or more slots parallel to the axis of the central axial bore, a container for holding objects passing through the tubular body, and a sensor unit configured to generate a first output by detecting a fill level of the container. The system further comprises a processor configured to determine different levels of the objects in the container as the objects fill the container or are removed from the container based on at least the first output.

These and other embodiments of the technology are described in further detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of the different embodiments may be realized by reference to the following drawings.

FIG. 1 depicts an example of a Cartesian or gantry robot with three independently moveable directions x-,y-, and z-.

FIG. 2 depicts a block diagram of a system in one embodiment.

FIG. 3 depicts a gripper unit having sensing capabilities in one embodiment.

FIG. 4. depicts a linear potentiometer and a fiber optic system in one embodiment.

FIG. 5. shows an illustrative specimen carrier with cutouts to allow optical access to a specimen container in one embodiment.

FIG. 6. shows an illustrative fiber optic system having multiple light sources in one embodiment.

FIG. 7 shows an exemplary laser emitting diode and photodiode optical sensing system in one embodiment.

FIGS. 8A-8B illustrate a ball screw assembly for closing gripper fingers of a gripper unit about a specimen container.

FIGS. 9A-9D show a worm drive assembly for closing gripper fingers of a gripper unit about a specimen container.

FIGS. 10A-10D show a slotted disc assembly for closing gripper fingers of a gripper unit.

FIGS. 11A-11B show a planetary gear assembly for closing gripper fingers of the gripper unit.

FIGS. 11C-11D show sections of the specimen gripper viewed from below planetary gear system.

FIG. 12 depicts a gripper unit that provides the capability for quick exchange of gripper fingers, in one embodiment of the invention.

FIGS. 13A-13C illustrate a release element in a first embodiment of the invention.

FIGS. 14A-14B illustrate the gripper finger release assembly in a closed position, in one embodiment of the invention.

FIG. 15 illustrates the gripper finger release assembly in an open position, in one embodiment of the invention.

FIG. 16 illustrates a release element in a second embodiment of the invention.

FIGS. 17A-17C illustrate a release element in a third embodiment of the invention.

FIG. 18A illustrates a typical gripper unit operable to grip a specimen container.

FIG. 18B illustrates a prior art robotic gripper that may be used as a strip-off element for caps.

FIG. 19 illustrates certain elements of an exemplary system comprising a chute arrangement, in one embodiment.

FIGS. 20A-20B illustrate close up views of a top chute comprising an element, in one embodiment.

FIG. 21 illustrates a top chute arrangement with a square shaped profile, in one embodiment of the invention.

FIG. 22 illustrates a close up view of the placement of a chute arrangement, in one embodiment.

FIG. 23 illustrates overview of an exemplary specimen output system in one embodiment.

FIG. 24 illustrates a flow chart for a method of releasing an object through a chute arrangement, in one embodiment of the invention.

FIG. 25 illustrates certain elements of an exemplary system comprising a chute arrangement and a sensor unit, in one embodiment.

FIG. 26 illustrates an exemplary ultrasonic sensor arrangement using two ultrasonic sensors, in one embodiment.

FIG. 27 illustrates an exemplary sensor arrangement using one ultrasonic sensor and one optical sensor, in one embodiment.

FIG. 28 illustrates a method for detecting the fill level of a container in one embodiment.

FIGS. 29A-29C illustrate various fill levels of a waste container in one embodiment of the invention.

FIG. 30 illustrates a method for detecting the fill level of a container with consumable objects, in one embodiment.

FIGS. 31A-31C illustrate various fill levels of a consumable container in one embodiment of the invention.

FIG. 32 illustrates an exemplary specimen output system in one embodiment of the invention.

FIG. 33 illustrates an arrangement for a bin frame with a door in one embodiment of the invention.

FIG. 34 illustrates a method to reset a waste container in one embodiment of the invention.

FIG. 35 illustrates a method to reset a consumable container in one embodiment of the invention.

FIG. 36 depicts a block diagram of an exemplary computer apparatus.

DETAILED DESCRIPTION

Embodiments of the present invention relate to a gripper unit, which may be referred to as a smart gripper or a specimen gripper. Some embodiments, as will be described in more detail below, are advantageous because they provide systems for gathering various data related to a specimen container, such as detection of the presence of a specimen container within the gripper unit, measurement of specimen container dimensions and weight, detection of specimen container contents, specimen tube identification, etc. Some or all of this information can be gathered during a specimen container transport or manipulation process. Further, because the gripper unit has the ability to characterize a specimen container as well as the specimen inside of it, there is no need to provide for separate characterization equipment, thereby reducing space requirements and expense. One embodiment of the invention provides an improved automated process by simultaneously performing multiple measurements and analytical processes on the specimen container, thereby providing for faster processing of the sample that resides in the specimen container. In some embodiments, measurements of a specimen container may be used to determine how many specimen containers can fit in a container with known dimensions.

The specimen container may be a sample tube. A sample tube may contain material for medical analysis, such as blood, serum, plasma, etc. In some cases, the sample tube may need to be decapped or recapped for storage, processing, discarding, etc. In some cases, the sample tube may need to be discarded when the storage time of the sample tube has expired or due to some other reasons.

The gripper unit may be used in a medical laboratory system for processing patient samples. The gripper unit may be equipped with one or more means for detecting information about specimen containers that it grips. In some embodiments, a gripper unit may be coupled to a robotic arm. Robotic arms may be used for transportation of specimen containers in various areas of a laboratory system, such as input, distribution, centrifuge, decapper, aliquotter, analyzer, output, sorting, recapping, and secondary tube lift areas.

A gripper unit according to embodiments of the invention may utilize plurality of gripper fingers to grip an object. The plurality of gripper fingers may comprise two or more (e.g., three, four or any suitable number) gripper fingers. In some embodiments, a jaw may be coupled to one end (gripping end) of a gripper finger to aid in gripping the object. The other end of the gripper finger may be coupled to an assembly or mechanism along with other gripper fingers that may be operable to control the gripper fingers for gripping the object.

A gripper unit may also be used as a decapper for removing caps from the specimen containers or as a recapper for attaching caps to the specimen containers. In such cases, the gripper unit may require specialized gripper fingers to perform different functions. However, the gripper fingers of a gripper unit may not be easily replaceable. Further, in some case, exchanging the gripper fingers may involve loose parts, such as screws or pins. Additionally, mounting or demounting of the fingers may require tools (e.g., a screw driver) and a certain amount of time (e.g., for removal of the screws). In order to demount the fingers, it may be necessary to destroy the parts, such as pins, that couple the gripper fingers to a body of the gripper unit. Further, in some cases, screws can fall into the system during removal of the fingers. Such problems can lead to sample processing delays since the gripper unit may not be usable during that period. One embodiment of the invention includes devices to enable replacement of gripper fingers without the need for tools and without the need to demount the entire gripper unit to exchange gripper fingers.

Specimen containers such as sample tubes may be used to hold specimens for medical analysis. In some cases, a specimen container may need to be discarded after the specimen has been processed or the storage time of the specimen container has expired. A gripper unit may also be used to grip and transport waste specimen containers to discard them into a waste container. However, in some cases, when the gripper unit releases the specimen container into the waste container, the specimen container may get stuck to the gripper unit and may not be automatically released. For example, the outside surface of the specimen container may be sticky due to contamination, glue from a label stuck to the specimen container, etc. In such cases, human intervention may be required to remove the specimen container to minimize the processing delays. Furthermore, contamination may be transported with the gripper fingers from one specimen container to another, thus further spreading the contamination. One embodiment of the invention are directed to systems and methods including a chute arrangement comprising an element implementing a strip-off feature that is used to restrain an object such as, a test tube, a cap, etc. gripped by the gripper fingers of a gripper unit, as the object is released by the gripper fingers.

As the waste objects are released in a waste container, the waste container may become full and may need to be emptied or replaced with another container. Similarly, a container with consumable objects may need to be refilled again when all the consumable objects have been removed. Another embodiment of the invention provides systems and methods to detect different fill levels of objects in a container using a sensor unit as the objects fill the container or are removed from the container. As the objects are dropped in the waste container, due to uneven geometries of the objects such as tubes, the container may not be optimally filled and uneven stacking of the objects may lead to heap building in the container. Even though a fill level detected by the sensor unit may indicate a maximum fill level due to the heap, a counter value that is used to keep track of the dropped objects may indicate that there may still be space left in the container. Embodiments of the invention provide for a method to reduce the effect of a possible error made in counting and a possible error made in measuring a fill level in the container by using both of the values and weighting the values to determine a more realistic fill level. These values may weighted differently as the objects fill the container. Thus, an operator or a user can react in time and can schedule maintenance actions accordingly.

Prior to discussing embodiments of the invention, description of some terms may be helpful in understanding embodiments of the invention.

A “cavity” may include a hole or an opening through which an object can pass through. In one embodiment, a cavity may be a hole in a gripper finger through which a sliding element can pass through for coupling the gripper finger to a gripper unit. The dimensions of the cavity may be such so as to allow the sliding element to easily slide through the cavity. In one embodiment, a cavity may have a circular cross-section with a diameter slightly bigger than the diameter of the sliding element (e.g., if the sliding element is cylindrical in shape with a circular cross-section). In one embodiment, the length of the cavity may depend upon the width of the gripper finger where the cavity is located. In embodiments of the invention, a cavity may be located at or near the non-gripping end of the gripper finger, where the gripper finger is coupled to the gripper unit.

In some embodiments, a cavity may also be a hole in a mounting structure of the gripper unit. In one embodiment, there may be plurality of cavities in the mounting structure for allowing the coupling of the plurality of gripper fingers to the body of the gripper unit. In some embodiments, a gripper finger release assembly may couple to the mounting structure of the gripper unit via two cavities, where each cavity may have different dimensions.

An element according to an embodiment of the invention may include a hollow tubular body comprising a first end and a second end. The first end of the body may include a plurality of slots to enable a plurality of gripper fingers gripping an object surrounded by the body of the element to separate from the object through the plurality of slots. The body of the element may have a square profile, a cylindrical profile or any suitable profile, which can accommodate an object that needs to be discarded, e.g., a specimen container, a cap, etc. The first end of the body may be open and integrated with an open end of each slot in a plurality of slots. In some embodiments, a second end of the body may be coupled to another device or unit. An element may also operate as a chute for directing a specimen container towards a container. In embodiments of the invention, the terms “stripping element”, “strip-off element” and “top chute” may be used interchangeably.

A “central axial bore” may include an opening along an axis of a body. A central axial bore may be defined by a body with any suitable shape and may be of any suitable length. For example, the body defining the central axial bore may have a volume slightly larger than the volume of an object with any suitable profile (square, cylindrical, etc.) and may have a length slightly longer than the object.

In one embodiment of the invention, an element body comprising a central axial bore may be configured to surround an object, e.g., a specimen container, within the central axial bore. For example, if the specimen container is a sample tube, the diameter of the bore may be large enough to accommodate a sample tube held by a plurality of gripper fingers within the bore. In embodiments of the invention, the central axial bore may include any hollow cylindrical forms including square shaped forms.

A “slot” may include a narrow opening. A slot may have any suitable length. In some embodiments, a slot may be sized so that it is slightly wider than a gripper finger or a jaw attached to the gripper finger. The slot may also have any suitable shape including a rectangular shape. In one embodiment, a slot may be elongated, arranged axially parallel to an axis of the element body and may be open at the first end of the element.

In embodiments of the invention, a plurality of slots may be integrated in the body of an element. The number of slots in the plurality of slots may be equal to the number of gripper fingers gripping an object surrounded by the body of the element. There may be two, three, four or a suitable number of slots in the plurality of slots to allow each gripper finger in the plurality of gripper fingers to grip the object through a slot. In one embodiment, plurality of slots includes at least two slots. Each of the plurality of slots may have a rectangular shape with a length smaller than a length of the body of the element and a width large enough to allow a gripper finger to move easily in and out of the slot. In one embodiment, the length of the element may be five inches, whereas, the length of each slot in the plurality of slots may be three inches, and the width of each slot may be one half inch of less in some embodiments.

A “container” or a bin may be used in a medical laboratory system to store or contain objects such as specimen containers (e.g., a sample tubes), caps, capillaries, pipettes, etc. A container may have a certain height (e.g., three feet or more), certain length (e.g., two feet or more) and certain width (e.g., one foot or more). The container may be of any shape with a suitable profile such as a rectangle, square, trapezoid, cylindrical, oval, etc. The container may have a specified maximum fill capacity, e.g., cubic centimeters, cubit feet, etc., to hold a number of objects. The container may be made of any suitable material such as plastic, metal, rubber, etc. The container may or may not have a lid. In one embodiment, a container may be used to store disposable objects such as test tube waste, test tube cap waste, capillary waste, and pipette tip waste, etc. In another embodiment, a container may be used to store consumable objects such as capillaries, secondary test tubes, caps, etc.

A “fill capacity” may include capacity of a container to hold plurality of objects. In one embodiment, the fill capacity of a container may include its capacity to hold same types of objects, for example, plurality of sample tubes, plurality of caps, etc. In one embodiment, fill capacity of a container may include the number of objects that can be filled in the container to reach a certain fill level based on a certain packing density. The fill capacity may depend on the volume of the container and the volume of the objects to be contained by the container.

A “fill level” may include a level of a container that has been filled with one or more objects. A fill level of “zero” may imply that the container is empty. In one embodiment, the fill level of a container may imply a distance to the bottom of the container. When the fill level is equal to close to a height of the container, the container may be full. The fill level of a container may vary based on the packing density of the objects deposited in the container. Further, the density may vary depending upon the number of objects already in the container. For example, when an object is dropped in an empty container, the packing density may be different as compared to when there are already twenty objects in the container.

A “sensor unit” may include one or more sensors or sensing devices to detect and respond to some type of input from the physical environment. For example, the input could be sound, motion, light, temperature, pressure, etc. The sensor unit may be configured to generate an output corresponding to the input or change in the input. The output may be in the form of an electrical signal, an optical signal or any other suitable form. Different sensors may have different sensitivity levels to detect the input. The sensors may include acoustic sensors, ultrasonic sensors, optical sensors, etc. An ultrasonic sensor may be based on the measurement of the property of acoustic waves with frequencies above the human audible range. An ultrasonic sensor may include a transceiver that emits a high frequency pulse of sound and receives and analyzes the properties of the echo pulse. In some embodiments, an ultrasonic sensor may include a short range sensor and a long range sensor.

The robotic arm architecture can differ in complexity dependent upon the given task. FIG. 1 depicts an example of a Cartesian or gantry robot 1000 with three independently moveable directions x-, y-, and z-. The gantry robot 1000 shown in FIG. 1 shows a simple robotic arm 1002 that can move up and down. More complex robotic arms may include, for example, a Selective Compliant Assembly Robot Arm (SCARA) or an articulated robotic arm with multiple joint arms.

In some embodiments of the invention, a gripper unit 1004, may be coupled to the robot arm 1002. The robot arm 1002 may be part of the gantry robot 1000 that is configured to move independently in three, orthogonal directions denoted as 1000A, 1000B and 1000C. As the gripper unit 1004 is transported by the robot arm 1002, the gripper unit 1004 may transport a specimen container 1006 held by the gripper unit 1004.

The gripper unit 1004 may have two or more moveable gripper fingers 1008, 1010 coupled to a body 1012 to grip the specimen container 1006. For example, the gripper fingers 1008, 1010 may move inwardly toward the specimen container 1006 until the specimen container 1006 is held in a fixed position between the gripper fingers 1008 and 1010. The gripper fingers 1008, 1010 may also be configured to spread outwardly to release the specimen container 1006. One embodiment of the invention provides an assembly to replace the gripper fingers 1008, 1010 without demounting or mounting the gripper unit 1004 and without the need of tools. The robot arm 1002 may be part of a laboratory automation system as further described with reference to FIG. 2.

FIG. 2 illustrates a block diagram of a system 1100 that may be utilized in a medical laboratory. The system 1100 may include an operator 1102 that may use a laboratory automation system 1104 to process samples (e.g., serum, plasma, packed red blood cells, etc.). In the exemplary embodiment, the laboratory automation system 1104 may include the robot arm 1002, a processing unit 1106, a gripper unit 1114, a sensor unit 1120, a chute arrangement 1122, a container unit 1128 and a feeder unit 1130. However, a number of other units (not shown) may be utilized by the laboratory automation system 1104. For example, the laboratory automation system 1104 may include an input module, a distribution area, a centrifuge, a decapper, a serum indices measurement device, an analyzer, a storage module, an aliquotter and an output/sorter in some embodiments of the invention. Further, the robot arm 1002, gripper unit 1114 and the sensor unit 1120 may be communicatively coupled to the processing unit 1106. The robot arm 1002 may be part of the gantry robot 1000.

The processing unit 1106 may include a processor 1108, a memory 1110, and an analog to digital converter (ADC) 1112. The processor 1108 may further include a programmable logic controller (PLC) 1108A. In one embodiment, the ADC 1112 can be part of the PLC 1108A. In some embodiments, the processor may include other suitable processing elements (not shown), such as a microprocessor, a digital signal processor, a graphics processor, a co-processor, a microcontroller, etc.

The processor 1108 may be configured to execute instructions or code in order to implement methods, processes or operations in various embodiments. In some embodiments of the invention, the processor 1108 may be configured to receive various outputs provided by different sensors that may be associated with the sensor unit 1120 and/or the gripper unit 1114 and communicatively coupled to the processor 1108. For example, in some embodiments of the invention, the sensor unit 1120 may include a sensing potentiometer may be communicatively coupled to the processor 1108. The potentiometer can be configured to produce an output based on a distance between the two gripper fingers in the plurality of gripper fingers when a specimen container is gripped in the plurality of gripper fingers. The processor 1108 can be configured to determine a dimension (e.g., a diameter) of the specimen container based on the output. In other embodiments, a load cell in the gripper unit may be communicatively coupled to the processor 1108. The processor 1108 can be configured to determine a weight of the specimen container based on an output of the load cell. In some embodiments, a light source coupled to a first gripper finger in a plurality of gripper fingers gripping a specimen container and a light source coupled to a second gripper finger in a plurality of gripper fingers gripping the specimen container may be coupled to the processor 1108. The processor 1108 can be configured to determine information (e.g., presence, length, liquid level and characteristics, etc.) associated with the specimen container gripped by the plurality of gripper fingers. The processor 1108 can also be configured to enable the robot arm 1002 to move the gripper unit 1114 to function as a tube gripper, a recapper or a decapper. In some embodiments, the processor 1108 can also be configured to disable movement of the gripper unit 1114 by the robot arm 1002 when the gripper fingers need to be exchanged. In some embodiments, the processor 1108 can be configured to determine different fill levels of objects in a container (e.g., a part of the container unit 1128) based on an output from one or more sensors in the sensor unit 1120, configured to detect the fill level of the container, and some pre-determined parameters, as the objects fill the container or are removed from the container.

The memory 1110 may be coupled to the processor 1108 internally or externally (e.g., cloud based data storage) and may comprise any combination of volatile and/or non-volatile memory such as, for example, buffer memory, RAM, DRAM, ROM, flash, or any other suitable memory device. In some embodiments, the memory 1110 may be in the form of a computer readable medium (CRM), and may comprise code, executable by the processor 1108 for implementing methods described herein. In some embodiments, the processor 1108 may be part of a computer system as described with reference to FIG. 36.

The memory 1110 may also store other information. In some embodiments, such information may include identification data for various specimens and specimen containers, gripper unit weight information, data correlating potentiometer outputs to specimen dimensions, data correlating load sensor outputs to specific weights, data correlating characteristics of different light signals to different container types and/or specimen types. By identifying the liquid characteristics of one or more liquid samples within the specimen container, the samples may be processed differently. For example, a specimen container with a first characteristics of one or more liquid samples within the specimen container could be directed to a storage unit by a gripper unit (coupled to a robotic arm), whereas, a specimen container with a second characteristics of one or more liquid samples within the specimen container could be directed to a centrifuge.

In some embodiments, the memory 1110 may also store data related to different types of gripper fingers that may be coupled to the gripper unit for performing different functionalities. For example, when the gripper unit is used as a tube gripper, a first set of gripper fingers may be used, whereas, when the gripper unit is used as a decapper, a second set of gripper fingers may be used, and, when the gripper unit is used as a recapper, a third set of gripper fingers may be used, etc. In some embodiments, information stored in the memory 1110 may also include data related to different types of release elements that may be used for exchange of gripper fingers.

The memory 1110 may store information relating to types and geometric dimensions of various objects (e.g., caps, sample tubes, secondary tubes, capillaries, pipettes, etc.) handled by the laboratory automation system 1104. In some embodiments, this information may be used by the processor 1108 to determine the number of objects that may fit in a container given a fill capacity of the container. In some embodiments, the memory 1110 may include a counter (e.g., a waste counter) to keep track of the number of objects dropped in a waste container. The memory 1110 may also include a counter (e.g., a consumable counter) to keep track of the number of objects removed from a consumable container. The consumable counter may be triggered by consumables that are detected by a sensor unit as they are being removed from the container or each time an object handling unit (e.g., a robotic arm) removes an object from the container. The memory 1110 may also store information about maximum fill levels associated with different containers in the container unit 1128 to store specific objects. In some embodiments, the memory 1110 may store geometric dimensions of each object handled by the laboratory automation system 1104 and also dimensions associated with different containers in the container unit 1128. The memory 1110 may also store information relating to different weight factors that may be used to correct the estimation of the number of objects dropped or remaining in a container.

The PLC 1108A may be configured to receive, store, analyze and/or process data from the ADC 1112, the gripper unit 1114 or any other unit interfacing with the gripper unit 1114. In some embodiments, the PLC 1108A may include one or more of a microcontroller, a digital to analog converter, an analog to digital converter, an amplifier, timer, memory, power circuit or any other support logic.

The ADC 1112 may be configured to receive an analog input (voltage or current) and convert it to a digital value corresponding to the magnitude of the analog input. The ADC 1112 may be implemented as a delta sigma converter, a high-speed pipeline converter, a successive approximation register or any such suitable type of converter.

The laboratory automation system 1104 may utilize the robot arm 1002 to grip a specimen container (e.g., sample tube) using the gripper unit 1114. The gripper unit 1114 may include a body 1116 and gripper fingers 1118 that are coupled to the body 1116. The gripper unit 1114 may be coupled to the sensor unit 1120 and the robot arm 1002. In some embodiments, the gripper fingers 1118 may be removably coupled to the body 1116 so that one or more of the gripper fingers may be replaced with another gripper finger. It is understood that the gripper unit 1114 may also include or interface with other units to enable the gripper unit perform the intended function.

In one embodiment, the chute arrangement 1122 may include a top chute 1124, and a bottom chute 1126 coupled to the top chute 1124. In one embodiment, the top chute 1124 may be in the form of an element implementing a strip-off feature to restrain an object gripped by the gripper fingers of a gripper unit as the object is released by the gripper fingers. In some embodiments, the top chute 1124 may be coupled to the bottom chute 1126 using an optional adapter or a spacer unit for compatibility or height adjustments. In embodiments of the invention, the gripper unit 1114 may grip an object from a rack or a carrier in an output module and drop it through the chute arrangement 1122 for discarding it into a waste container that may be part of the container unit 1128. In one embodiment, the chute arrangement 1122 may include only a single chute through which objects such as test tubes, caps, capillaries, pipettes, etc. may be dropped into a container.

The container unit 1128 may include one or more containers. For example, the container unit 1128 may include one or more waste containers to store waste or disposable objects such as test tubes, test tube caps, capillaries and pipettes, etc. The container unit 1128 may also include one or more consumable containers to store consumable objects such as capillaries, secondary test tubes, caps, etc.

The feeder unit 1130 may include any suitable feeder system to feed an object into a container that may be part of the container unit 1128. For example, the feeder unit 1130 may include a bowl feeder, a step feeder, a wall feeder, etc. to feed objects such as capillaries, test tubes, caps, pipettes, etc. to a container.

The sensor unit 1120 may include plurality of sensors, wherein one or more sensors of the plurality of sensors may be coupled to the gripper unit 1114. The sensor unit 1120 may be configured to detect/provide information associated with the specimen containers that may be used by the processing unit 1106 for efficient processing of samples. In some embodiments, the information provided by various sensors may be used to determine dimensions of the specimen container (e.g., diameter, length, etc.), the cap color, level and characteristics of one or more samples contained in the specimen container, etc. For example, the sensor unit 1120 may include a sensing potentiometer for determining a dimension (e.g., a diameter) of the specimen container, and/or an optical/fiber optic sensor system for determining a presence of the specimen container and/or liquid characteristic/level, a length of the specimen container, etc. In one embodiment, the gripper unit 1114 may be configured to work in conjunction with a load cell to determine a weight of the specimen container.

In one embodiment, one or more of the sensors in the sensor unit 1120 may be in close proximity of the chute arrangement 1122. The sensor unit 1120 may be configured to detect the presence of an object passing through the chute arrangement 1122 into a waste container. The sensor unit 1120 may also be configured to detect a fill level of a waste container and/or a consumable container. A number of such waste containers and/or consumable containers may be part of the container unit 1128. In some embodiments, the sensor unit 1120 may comprise a short range sensor such as an ultrasonic sensor or an optical sensor to detect a falling object through the chute arrangement 1122 and a long range sensor such as an ultrasonic sensor to detect a fill level of the container.

The gripper fingers 1118 may include a plurality of gripper fingers including a first gripper finger, a second gripper finger, etc. The plurality of gripper fingers may comprise two or more gripper fingers. Each gripper finger may take a form of an elongated structure that is capable of gripping an object such as a sample tube or a cap in collaboration with one or more other gripper fingers. In some embodiments, an exemplary gripper finger may have a rectangular, axial and/or longitudinal, cross-section with predetermined thickness (e.g., one quarter of an inch or more) and length (e.g., three inches or more). Suitable gripper fingers may be rigid or may have one or more pivoting regions.

In one embodiment, the gripper fingers 1118 and the sensor unit 1120 are coupled to the body 1116. The body 1116 may be in the form of a support structure or a housing. It may have any suitable shape including a square or rectangular vertical or horizontal cross section. The gripper fingers 1118 can be capable of moving with respect to the body 1116, while the sensor unit 1120 may be stationary and fixed to and/or enclosed by the body 1116. In one embodiment, the body 1116 may include one or more mounting structures so that the gripper fingers 1118 are coupled to the one or more mounting structures. In some embodiments, the gripper fingers 1118 may be coupled to the one or more mounting structures through a release element such that one or more gripper fingers may be replaced (e.g., for service or repair) without demounting/mounting the gripper unit 1114. In one embodiment, one or more sensors of the sensor unit 1120 may be coupled to the one or more mounting structures. The body 1116 may be made of any suitable material including metal or plastic. In some embodiments, the body 1116 may include or be coupled to a gripper finger release assembly comprising one or more release elements. This release assembly allows one to easily and quickly exchange gripper fingers without using tools.

In some embodiments, the body 1116 may include or couple to one or more assembly units that allow for opening and closing of the gripper fingers 1118. For example, the body 1116 may include a worm drive assembly, a slotted disc assembly or a planetary gear assembly for closing or opening the plurality of gripper fingers about the specimen container. These assembly units are described in further detail below.

In one embodiment, the gripper unit 1114 may grip an object using the gripper fingers 1118 from a carrier or a container holding a plurality of such objects. One or more sensors coupled to the gripper unit 1114 may determine various characteristics associated with the object (e.g., dimensions, weight, presence, type, etc.) while the object is gripped by the gripper fingers 1118. In some embodiments, if the object contains a specimen, specimen characteristics may also be determined. If the object is a waste object and needs to be disposed, the gripper unit 1114 may drop the object through the chute arrangement 1122 into one of the waste containers in the container unit 1128. The sensor unit 1120 may detect passing of the object through the chute arrangement 1122 into the container and also detect a fill level of the container as the objects fill the container. Alternatively, if the object is a consumable object, the gripper unit 1114 may grip an object from a consumable container and transport the gripped object to another module for further processing. The processor 1108 may determine a fill level of the container as the objects fill the container or are removed from the container based on an output from the sensor unit 1120 and some other parameters associated with the object and the container. In some embodiments, one or more of the gripper fingers 1118 may be replaced or removed for repair or service, etc. without demounting the entire gripper unit 1114.

I. Sensing Specimen Gripper

One embodiment of the invention provides systems and methods for gathering data related to a specimen container. For example, data such as the presence of a specimen container within a gripper unit, the measurement of specimen container dimensions and weight, detection of specimen container contents, specimen tube identification, etc. may be gathered. Embodiments provide an improved automated process by simultaneously performing multiple measurements and analytical processes on the specimen container, thereby providing for faster processing of the sample that resides in the specimen container.

FIG. 3 depicts a gripper unit 1200 having sensing capabilities in one embodiment.

The gripper unit 1200 may include a sensing potentiometer 1202, first and second mounting structures 1204 and 1206, gripper fingers 1208 and 1210, an optical sensor unit 1218, and a pneumatic actuator 1224. A load sensor unit 1226 may be used in conjunction with the gripper unit 1200. The gripper unit 1200 may be coupled to the robot arm 1002 (in FIG. 1) and can grip a specimen container 1212 using the gripper fingers 1208 and 1210.

In some embodiments, the specimen container 1212 is gripped by replaceable jaws 1214 and 1216 coupled to the gripper fingers 1208 and 1210, respectively. The replaceable jaws 1214, 1216 can have any suitable shape or size, and are desirable since they can be replaced to accommodate sample tubes of different shapes. For example, the jaws 1214, 1216 may have facing convex surfaces to accommodate the convex surface of the specimen container 1212. Thus, in some embodiments, surfaces of the jaws 1214, 1216 may be cooperatively configured with respect to a surface of the specimen container 1212. In embodiments of the invention, the jaws 1214, 1216 can also be easily replaced when they are worn or defective. In some embodiments, the replaceable jaws can be made of any suitable material including a soft or hard plastic material. In some embodiments, the jaws 1214, 1216 may be integrally formed with the gripper fingers 1208, 1210, thus forming unitary structures.

In one embodiment, the specimen container 1212 may have a cylindrical shape with a circular cross-section. In one embodiment, a diameter of the specimen container 1212 can be interpreted as a width of the specimen container 1212 (i.e., as measured by an outer diameter of the specimen container 1212) or a length of a straight line passing through the center of the specimen container 1212 and connecting with two points on the surface of the specimen container 1212.

In one embodiment, the specimen container 1212 may have a cap 1220. The cap 1220 may have a cylindrical shape with a circular cross-section and a diameter slightly larger than the diameter of the specimen container 1212 and a length relatively shorter than the length of the specimen container 1212. It will be understood that other shapes and sizes of the specimen container 1212 and the cap 1220 are possible that can be gripped by the gripper unit 1200. The cap 1220 may have a specific color such as red, green, or blue.

The mounting structures 1204 and 1206 may be part of a body 1230 of the gripper unit 1200. In one embodiment, the mounting structures 1204 and 1206 have a similar shape and each mounting structure 1204, 1206 is coupled to a corresponding gripper finger 1208, 1210. For example, the mounting structure 1204 is coupled to the gripper finger 1208 and the mounting structure 1206 is coupled to the gripper finger 1210. In one embodiment, each of the mounting structures 1204 and 1206 comprise a rectangular structure with a certain thickness (e.g., quarter inch) and means for coupling to various sensor units and the gripper fingers.

In one embodiment, the sensing potentiometer 1202 is disposed between the first and second mounting structures 1204 and 1206. In one embodiment, the sensing potentiometer 1202 includes housing with a rectangular cross-section and support for coupling to the mounting structures 1204 and 1206. The sensing potentiometer 1202 may include a resistive element with varying resistance. In one embodiment, the sensing potentiometer 1202 is a linear potentiometer which provides a resistance value that changes proportionally to the distance between the gripper fingers 1208 and 1210. The sensing potentiometer 1202 may be configured to produce an output based on a distance between the gripper fingers 1208 and 1210. In one embodiment, the output is a voltage value corresponding to the resistance value of the linear potentiometer 1202 that may be provided to the PLC 1108A. When a specimen container such as the specimen container 1212 is gripped by the gripper fingers 1208 and 1210, a diameter of the specimen container 1212 can be determined based on a signal corresponding to the resistance value of the linear potentiometer 1202. The gripper fingers 1208, 1210 can move inwardly towards each other when they are used to secure the specimen container 1212.

In one embodiment, the pneumatic actuator 1224 is disposed between the first and second mounting structures 1204 and 1206. In one embodiment, the pneumatic actuator 1224 includes housing with a rectangular cross-section and support means for coupling to the mounting structures 1204 and 1206. In one embodiment, the pneumatic actuator 1224 is configured to control the movement of the gripper fingers 1208, 1210. In some embodiments, the positions of gripper fingers 1208 and 1210 can be determined based on the control signal to the pneumatic actuator 1224. In one embodiment, the diameter of the specimen container 1212 can be determined based on a signal sent to (or received from) the pneumatic actuator 1224 indicating the position of one or both gripper fingers 1208, 1210. In some embodiments, the pneumatic actuator 1224 may consist of a piston, a cylinder and valves or ports.

In one embodiment, the optical sensor unit 1218 may be arranged between the first and second mounting structures 1204 and 1206 using support means. The optical sensor unit 1218 may include one or more optical sensors. For example, the gripper unit 1200 may have an optical sensor (e.g. OPB732WZ by Optek) including a light emitting diode and a phototransistor. The light emitting diode can transmit light toward the cap 1220 of the specimen container 1212 and the phototransistor can sense light reflected from the cap 1220. The output current of the phototransistor can be proportional to the amount of light reflected, providing an indication of the distance between the phototransistor of the optical sensor 1218 and the top of the cap 1220.

The gripper unit 1200 can be configured to pick up the specimen container 1212 at a uniform distance from the bottom of the specimen container 1212, allowing the specimen container length from the bottom of the tube 1212 to the top of the cap 1220 to be determined based on the distance between the optical sensor 1218 and the cap 1220. For example, a voltage corresponding to the current output of the phototransistor can be received by the PLC 1108A and can be used to determine the distance between the optical sensor 1218 and the cap 1220 and corresponding length of the specimen container 1212. In some cases, the length of the specimen container 1212 may be used to identify the type of sample contained in the specimen container 1212 if samples of the same type are in samples tubes with similar lengths. In one embodiment, a camera controller 1222 can be used to provide instructions to and receive data from the optical sensor 1218. The light reflected from the cap 1220 may be used for other purposes as well. For example, in some embodiments, the color of the cap 1220 can be determined thereby identifying the particular specimen container associated with the cap.

Some embodiments of the invention are directed to methods. Such methods include transmitting light generated by a light emitting diode directed towards a cap of the specimen container (e.g., cap 1220 of the specimen container 1212), and receiving light reflected from a surface of the cap of the specimen container by a photo transistor communicatively coupled to a processor (e.g., processor 1108). The photo transistor is configured to generate a signal corresponding to a quantity of reflected light from the surface of the cap of the specimen container.

In some embodiments, the optical sensor 1218 of the gripper unit 1200 is a camera, such as a CMOS color camera (e.g., OV7680 Color CMOS VGA by OmniVision). An optical sensor that is a camera can provide information about the specimen container, such as a cap color. The camera can also provide information about a rack of specimen tubes (e.g., sample tubes), such as filled and unfilled rack positions.

A load sensor unit 1226 may be used in conjunction with gripper unit 1200. The load sensor unit 1226 may comprise a load cell 1228 that may operate as a transducer to convert a force into an electrical signal. In one embodiment, the load sensor unit 1226 may be arranged on top of the gripper unit 1200. The load cell 1228 can generate a signal that can be used to determine a weight, such as a combined weight of the specimen container 1212 and the gripper unit 1200. For example, an output of the load cell 1228 may be provided to the PLC 1108A via the ADC 1112. In one embodiment, the output is on the order of a few millivolts and may require amplification by an amplifier. Some types of load cells may include hydraulic load cells, pneumatic load cells, or strain gauge load cells. The PLC 1108A can further process the output of the load cell 1228 to determine a weight of the specimen container 1212. The load cell 1228 may be, e.g. an FS20 load cell by Measurement Specialties. A known weight of the gripper unit 1200 can be subtracted from the combined weight to determine the weight of the specimen container 1212. This weight can be used, for example, to aid in balancing the centrifuge buckets in a centrifuge.

Some embodiments of the invention are directed to methods. Such methods may include gripping the specimen container using a plurality of gripper fingers, and generating, by a load cell, an output. In one embodiment, the gripped specimen container is weighted in a lifted or elevated position. A processor communicatively coupled to the load cell may determine a weight of the specimen container based on the output.

Certain components of the gripper unit 1200 described with reference to FIG. 3 can be further understood as described with reference to the system diagram of FIG. 4. In FIG. 4, as in FIG. 3, the gripper fingers 1208 and 1210 of the gripper unit are configured to grip a specimen container such as the specimen container 1212. The gripper unit 1200 may comprise a linear potentiometer 1310 (e.g., corresponding to the linear potentiometer 1202 of FIG. 3) that may be used to determine a weight of the specimen container 1212. The gripper unit 1200 may also include one or more optical sensor systems for determining information related to the specimen container 1212 and/or the contents of the specimen container 1212.

The linear potentiometer 1310 may include mechanical components 1316 and 1318 coupled to the gripper fingers 1208 and 1210, respectively. The linear potentiometer 1310 may include a resistor 1312 (e.g., 5 KΩ) and a resistor 1314 (e.g., 5 KΩ). In one embodiment, a power supply 1302 may represent a positive supply voltage (e.g., VCC) and a power supply 1304 may represent a negative supply voltage (e.g., GND). As gripper fingers 1208 and 1210 slide inward to grip the specimen container 1212, the mechanical components 1316 and 1318 move relative to one another, changing the resistance value of the linear potentiometer 1310. A signal having a voltage value proportional to the resistance value of the linear potentiometer 1310 can be received by the PLC 1108A via the ADC 1112. The diameter of the specimen container 1212 can be determined based on the voltage value. It will be recognized that other sensing devices can be used in lieu of a linear potentiometer to determine the diameter of a specimen container.

Voltages corresponding to resistance values of the linear potentiometer 1310 can be calibrated in association with positions of the gripper fingers 1208 and 1210 (e.g., at full open, full close, and 1-100 intermediate positions, such as two to thirty intermediate positions, e.g. ten positions). In this manner, nominal voltage ranges can be associated with various tube diameters as well as full open, full close, and/or “illegal” conditions. Illegal conditions may indicate an error state. For example, if the gripper unit was commanded to grip a specimen container and a detected voltage (associated with the linear potentiometer 1310 and/or pneumatic actuator 1224) indicates a full closed condition, an error has occurred because the closed condition indicates that no specimen container was gripped. In another example, if the gripper unit was commanded to grip the specimen container and a detected voltage indicates a full open condition, an error has occurred because the gripper fingers 1208 and 1210 have not closed on a specimen container, which could indicate an obstruction or a binding in the gripper unit.

The configuration of one or more sensors in association with the gripper unit 1200 allows development of truth tables. The truth tables may associate various conditions, such as full open, full closed, and diameter of tube gripped, with values corresponding to distances between the gripper fingers 1208 and 1210. An illegal condition may occur when a determined distance between the gripper fingers 1208 and 1210 does not match an acceptable value for the current state of the gripper unit. For example, if the gripper unit has been commanded to grip a tube but a diameter determined by the linear potentiometer 1310 for the tube is not an accepted value for tube diameter, an illegal condition may occur. In another example, if a gripper is at a full open position as detected by the linear potentiometer 1310 and a presence sensor indicates the presence of a tube, a truth table may associate this combination of conditions with a potential “dangling tube” condition. An alert could be generated based on the dangling tube condition by the PLC 1108A that may be provided to the operator 1102.

Some embodiments of the invention utilizing the potentiometer may also include methods. Such methods may comprise gripping the specimen container using a plurality of gripper fingers, and then generating, by a sensing potentiometer, an output based on a distance between two gripper fingers in the plurality of gripper fingers. A processor (e.g., processor 1108) coupled to the sensing potentiometer may determine a dimension such as a diameter of the specimen container based on the output.

In some embodiments, an optical sensor system may be used to detect whether a specimen container is present between the gripper fingers. In another example, an optical sensor system can be used to determine one or more liquid levels of sample material (e.g., serum, plasma, gel, packed red blood cells etc.) within the specimen container. Where multiple liquid types are present in a specimen container, the locations of interfaces between different liquid types can be determined. An optical sensor system can be used to determine a serum index. The liquid characteristics of one or more liquids within the specimen container can also be determined based on an attenuation of a signal from the light source as detected by the light receiver. In some embodiments, an optical sensor system can be used to determine one or more dimensions of a specimen container, such a length of a specimen container. An optical sensor system may further determine the presence and/or color of a cap of a specimen container.

The optical sensor system can include a radiation source (such as a light source) and a radiation receiver (such as a light receiver). A typical light source emits electromagnetic radiation in the visible spectrum. The term “light” as used herein may refer to any radiation. The radiation source may be, for example, a fiber optic source, a light emitting diode (LED), a laser diode, or a laser. The radiation receiver (also referred to as a “detector”) may be, for example, a fiber optic receiver or a photodiode. An amplifier may be coupled to the output of the detector for amplifying the received attenuated signals.

In one embodiment, an optical sensor system can include a fiber optic system including a fiber optic source 1306 and a fiber optic receiver 1308, as illustrated in FIG. 4. The fiber optic source 1306 may be coupled to a transmitter 1320 (e.g., U2-Keyance Transmitter) and the fiber optic receiver 1308 may be coupled to a receiver 1322 (e.g., U2-Keyance Receiver). In one embodiment, the fiber optic system is part of the sensor unit 1120. The fiber optic source 1306 and the fiber optic receiver 1308 may be embedded with and coupled to the surfaces of the gripper fingers 1208 and 1210, respectively, and/or the jaws 1214 and 1216. In other embodiments, the fiber optic source 1306 and the fiber optic receiver 1308 may be attached to elongated structures forming at least part of the gripper fingers 1208, 1210. Alternatively, the fiber may be threaded through the gripper fingers. It will be recognized that other configurations may be used to connect the fiber to the surfaces of the gripper fingers. In some embodiments, an inline right angle connector or adapter is used in locations where the fiber traverses a corner that exceeds the bending tolerance of the fiber.

The presence or absence of the specimen container 1212 between the gripper fingers 1208 and 1210 can be determined based on a signal received by the PLC 1108A from the fiber optic receiver 1308. For example, if no specimen container is located between the gripper fingers 1208 and 1210, light emitted from the fiber optic source 1306 is received by the fiber optic receiver 1308. In this example, a signal is received by the PLC 1108A from the fiber optic receiver 1308 indicating the absence of a specimen container. When a specimen container is located between the gripper fingers 1208 and 1210, the light emitted from the fiber optic source 1306 is not received by the fiber optic receiver 1308 because the specimen container blocks some or all of the emitted light from the fiber optic source 1306. In this case, a signal is received by the PLC 1108A from the fiber optic receiver 1308 indicating the presence of a specimen container.

In some embodiments, measurements can be performed using the fiber optic system. For example, gripper fingers with the fiber optic source 1306 and the fiber optic receiver 1308 can be moved along a vertical axis relative to the specimen container 1212. Such a measurement is performed while the gripper fingers are not gripping the specimen container 1212. For a specimen container length measurement, gripper fingers with the fiber optic source 1306 and the fiber optic receiver 1308 can be lowered from a point above the specimen container 1212 (where the fiber optic receiver 1308 receives a beam of light emitted from the fiber optic source 1306 because the specimen container 1212 does not break the beam), along the length of the specimen container 1212 (where the fiber optic receiver 1308 does not receive a beam of light emitted from the fiber optic source 1306 because the specimen container 1212 breaks the beam), to a point below the specimen container 1212 (where the fiber optic receiver 1308 receives a beam of light emitted from the fiber optic source 1306 because the specimen container 1212 does not break the beam). The length of the specimen container 1212 can be determined based on the distance traversed by the gripper fingers over which the beam from the fiber optic source 1306 was attenuated or broken. One or more liquid levels in the specimen container 1212 can be similarly determined.

FIG. 5 shows an illustrative specimen carrier with cutouts to allow optical access to the specimen container. A specimen carrier 1400 used to transport a specimen container may have one or more slots 1402 to allow a specimen container 1406 to be visible to the optical sensing system. Slots 1402 may have a vertical orientation to allow the gripper unit to perform measurements by traversing the length of the specimen container 1406 while the specimen container is held upright within the specimen carrier 1400. In some embodiments, the specimen carrier 1406 may allow for gripper fingers 1208, 1210 to move below the underside of the specimen container 1406 as shown by the space 1404 below the specimen container 1406. For example, the specimen carrier may have a lip or other feature to support the specimen container to create space between the underside of the specimen container and the lower interior surface of the specimen carrier. The gripper fingers 1208, 1210 can determine the length of the tube by moving along the length of the specimen container 1406 from above the top of the specimen container to below the underside of the specimen container, such that a radiation source and/or radiation receiver are aligned with one or more slots 1402.

In an alternative embodiment of a fiber optic system, the fiber optic receiver 1308 determines an amount by which light emitted from the fiber optic source 1306 is attenuated. For example, the amount by which the light is attenuated relative to a baseline light level may be determined. The baseline light level may be a predetermined value or may be established during a state when it is known that no obstruction exists between fiber optic source 1306 and the fiber optic receiver 1308.

The optical sensor system may include two or more light sources. Each light source may have an associated light receiver, such as a fiber optic receiver or photodiode. Alternatively, light from two or more fiber optic sources may be detected by a single light receiver using an optical device for mixing light. Alternatively, a beam combiner may be used to direct light from different light sources in parallel toward a specimen container.

FIG. 6 shows an illustrative fiber optic system 1500 having multiple light sources. In one embodiment, the fiber optic system 1500 is part of the sensor unit 1120. The fiber optic system 1500 includes a first light source 1502 and a second light source 1504 coupled to a first gripper finger 1510 and a detector 1506 coupled to a second gripper finger 1512.

The first gripper finger 1510 and the second gripper finger 1512 may be part of a gripper unit, such as, the gripper unit 1200. The first light source 1502 is arranged to apply a first signal beam having a first characteristic wavelength (in the range of 200 nm-1700 nm, such as between 800 nm-1200 nm, e.g., 980 nm) to a beam combiner (not shown) which directs the first transmitted signal toward a location on a specimen container 1508. The first light source can be detected by the detector 1506, such as a fiber optic receiver or photodiode. The second light source 1504 can be arranged to apply a second signal beam having a second characteristic wavelength (e.g., in the range of 200 nm -1700 nm, such as between 1000 nm-1400 nm, e.g., 1050 nm) to the beam combiner at a slightly shifted position from the first signal beam. The beam combiner can direct the second emitted signal beam parallel to the beam path of first emitted signal beam toward a slightly different location on the specimen container 1508. The second signal beam can be detected by the detector 1506. The output signal of the detector 1506 can be received by the processor 1108 for storage (e.g., in the memory 1110) and/or processing. The wavelength of light for the first light source 1502 may be selected such that the attenuation of the light through a particular fluid is minimal, allowing the first light source 1502 to be used as a reference. The wavelength of light for the second light source 1504 may be selected such that the attenuation is predictable for a fluid of interest.

Characteristics of various liquids within a specimen container (e.g., specimen container 1212), such as the opacity of the liquids, may vary. The varying liquid characteristics allow determination of liquid type of material in a specimen container based on a determination of the attenuation of light passing through the liquids. Measurement of the quantity of each of multiple liquids in a container may also be determined in this way. For example, serum and gel are mostly transparent to visible light while red blood cells are substantially opaque. Further, gel is transparent to infrared light while red blood cells and serum are substantially opaque. Accordingly, when a specimen container has gel (e.g., a synthetic gel for separating serum from red blood cells), it is possible just using infrared light to “see through” different sections. The infrared light reading is strong when the infrared light beam passes through air, drops when the infrared light beam is directed toward the serum, is relatively strong when directed toward the gel, and drops again when directed toward the red blood cells. A sample level detection system is described in detail in U.S. Provisional Patent Application No. 61/556,667, filed Nov. 7, 2011 and entitled “Analytical System and Method for Processing Samples” and PCT/US2012/063931 entitled “System and Method for Processing Samples,” filed on Nov. 7, 2012, which are incorporated by reference in their entirety for all purposes.

Laky or chylous samples, of lipemic, hemolytic or icteric patients commonly interfere with other laboratory tests that use optical methods. Thus, for reliable sample handling automation, it is desirable to measure serum index before a sample is committed to an analyzer for testing to avoid erroneous measurements. Liquid characteristics of laky or chylous liquids can be determined based on an attenuation of a signal from the light source as detected by the light receiver. Liquid characteristics used in specimen processing are described in detail in U.S. Provisional Patent Application No. 61/701,360, filed Sep. 14, 2012 and entitled “Analytical System with Capillary Transport,” which is incorporated by reference.

FIG. 7 shows fingers of a gripper unit (e.g., gripper unit 1200) with an illustrative laser emitting diode (LED) and photodiode optical sensing system 1600. In one embodiment, the optical sensing system 1600 is part of the sensor unit 1120. It will be recognized that an optical sensor system including one or more LEDs and one or more photodiode detectors could be used in lieu of the fiber optic system described above. In one embodiment, a first LED 1608 having a first wavelength and a second LED 1610 having a second wavelength may be coupled to the surface of a first gripper finger (or gripper fingertip or jaw) 1602 that faces a specimen container 1606. A photodiode 1612 may be coupled to a second gripper finger 1604 opposite the first gripper finger 1602 such that it's in a line of sight of the LEDs 1608 and 1610. It will be understood that for wired LEDs 1608, 1610 and the photodiode 1612, wirings may pass through the first and second gripper fingers 1602, 1604. Alternatively, wireless components may be used.

The photodiode 1612 may be configured to receive the light transmitted by the LEDs and convert it to a current or voltage that may be provided to the PLC 1108A for further processing, e.g., for determining liquid level or characteristics and/or length of the tube, etc. The photodiode 1612 may be silicon based, germanium based or any other suitable type of photodiode.

Some embodiments of the invention may be directed to methods. Such methods may include transmitting, by a light source, an optical signal, the light source coupled to a first gripper finger in a plurality of gripper fingers gripping the specimen container. The method also includes receiving, by a light receiver, the optical signal, the light receiver being coupled to a second gripper finger in the plurality of gripper fingers gripping the specimen container, and then determining, by a processor (e.g., processor 1108) coupled to the light source and the light receiver, information associated with the specimen container gripped by the plurality of gripper fingers. Such information may relate to the presence or absence of a specimen container between the gripper fingers, the type of liquid or liquids inside of the specimen container, the type or specimen container, the height of the liquid in the specimen container, the height of the specimen container, etc.

Gripper Unit Closure Assemblies

In various embodiments, the gripper unit may have various assemblies for closing the gripper fingers to clasp a specimen container. Some embodiments allow the gripper unit to grip tubes of different diameters and heights.

In some embodiments, closure of the gripper fingers about a specimen container is caused by rotation of gripper fingers around a pivot point. FIGS. 8A-8B illustrate a ball screw assembly for closing gripper fingers 1702 of a gripper unit 1700 using a ball screw 1704 to cause rotation around a pivot point 1706. A ball screw linear actuator translates rotational motion to linear motion. The ball screw 1704 uses ball bearings in a helical raceway to form a precision screw. FIG. 8A shows the gripper unit 1700 with ball screw driven gripper fingers 1702 in a closed position. FIG. 8B shows the gripper unit 1700 with ball screw driven gripper fingers 1702 in an open position. The downward translation of the ball screw 1704 causes the gripper fingers 1702 to pivot outwards. Upward translation of the ball screw 1704 causes the gripper fingers 1702 to pivot inward. The inward pivoting of the griper fingers 1702 can cause the gripper fingers 1702 to close about the specimen container 1700. In one embodiment, the gripper unit 1700 is similar to the gripper unit 1114 with the ball screw assembly coupled to the body 1116.

FIGS. 9A-9D show a worm drive assembly for closing gripper fingers 1802 of a gripper unit 1800 about a specimen container 1804. FIG. 9A shows the gripper unit 1800 with worm gear driven gripper fingers 1802 in a closed position. When closed about the specimen container 1804, worm gear driven gripper fingers 1802 clamp the specimen container 1804. FIG. 9B shows the gripper unit 1800 with worm gear driven gripper fingers 1802 in an open position (e.g., to release specimen container 1804).

FIG. 9C shows an illustrative worm drive assembly. A worm drive can include a worm gear 1808 and a worm 1806. The rotation of the worm 1806 drives rotation of the worm gear 1808. FIG. 9D shows a worm drive in the context of the gripper unit 1800. The worm 1806 can cause the rotation of multiple worm gears 1808-1814. Each worm gear may be associated with a gripper finger 1802. As the worm 1806 turns, worm gears 1808-1814 can rotate, causing the gripper fingers 1802 to pivot. Rotation of the worm 1806 in a first direction can cause the gripper fingers 1802 to pivot inward toward the specimen container 1804. Rotation of the worm 1806 in a second direction can cause the gripper fingers 1802 to pivot (e.g., to release the specimen container 1804).

In one embodiment, the gripper unit 1800 is similar to the gripper unit 1114 such that the worm drive assembly can be coupled to the body 1116. In some embodiments, one or more holes may be added to allow the gears to be mounted on the gripper fingers.

In some embodiments, closure of the gripper fingers about a specimen container is caused by movement of gripper fingers through a rotating disc with angular slots. FIGS. 10A-10D show a slotted disc assembly for closing gripper fingers 1902 of a gripper unit 1900. FIG. 10A shows the gripper unit 1900 with slotted disc driven gripper fingers 1902 in an open position. FIG. 10B shows a section of the gripper unit viewed from above slotted disc 1904 with slotted disc driven gripper fingers 1902 in an open position. FIG. 10C shows a gripper unit with slotted disc driven gripper fingers 1902 in a closed position. FIG. 10D shows a section of the gripper unit viewed from above slotted disc 1904 with slotted disc driven gripper fingers 1902 in a closed position. As slotted disc 1904 rotates, gripper fingers 1902 are urged along the paths defined by slots 1906 in slotted disc 1904. Rotation of disc 1906 in a first direction can cause gripper fingers 1902 to move along slots 1906 inward toward a closed position. Rotation of disc 1906 in a second direction can cause gripper fingers 1902 to move along slots 1906 outward toward an open position. The spline shape of slots 1906 shown in FIGS. 10A-10D can be advantageous in that the angle under which force is applied by rotating disc 1904 to gripper finger 1902 is always the same. It will be recognized that other shapes, such as a linear slot shape, may be used.

In one embodiment, the gripper unit 1900 is similar to the gripper unit 1114 such that the slotted disc assembly can be coupled to the body 1116.

In some embodiments, closure of the gripper fingers about a specimen container is caused by rotation of a planetary gear having a planet gear coupled to each gripper finger 1952 of a gripper unit 1950. FIGS. 11A-11B show a planetary gear assembly for closing gripper fingers 1952 of the gripper unit 1950. FIG. 11A shows a gripper unit with planetary gear driven gripper fingers 1952 closed about a specimen container 1954. FIG. 11B shows a gripper unit with planetary gear driven gripper fingers 1952 in an open position.

FIGS. 11C-11D show sections of the gripper unit viewed from below planetary gear system 1956. A planetary gear system can have one or more outer gears (i.e., “planet gears”). The planet gears may revolve around a central gear (i.e., “sun gear”). FIG. 11C shows a section of the gripper unit with planetary gear driven gripper fingers 1952 in a closed position corresponding to FIG. 11A. The point of attachment between gripper finger 1952 and a planetary gear of the planetary gear system 1956 is shown at 1958. As planet gears 1956 rotate, gripper fingers 1952 rotate to an open position as shown in FIG. 11D, corresponding to FIG. 11B.

In one embodiment, the gripper unit 1950 is similar to the gripper unit 1114 such that the planetary gear assembly can be coupled to the body 1116.

Embodiments allow gripping different tube diameters and lengths with reliable and fast to repair features. The gripper unit in accordance with various embodiments makes multiple measurements simultaneously affording a better method of managing the specimen containers. For example, by determining the diameter, height, length and the cap color of the specimen container before picking it up, the embodiments provide faster speed and further qualify that it's safe to optimally route the specimen containers to other modules for further processing. In some embodiments, some of the measurements associated with the specimen container may be used by a processor to determine the number of specimen containers that may fit in a container given a fill capacity of the container. Such information may be used to determine a fill level of the container so that the container may be emptied, replaced or refilled accordingly.

II. Removable Specimen Gripper Fingers

Embodiments of the invention include devices to enable replacement of gripper fingers without the need of tools or without the need to demount the entire gripper unit for exchange of gripper fingers. In some embodiments of the invention, a gripper finger may comprise means for coupling to a gripper finger release assembly that can enable a quick exchange of the gripper finger. For example, a gripper finger may comprise a cavity or a hole for coupling to a release assembly and to the gripper unit. Note that in this specification, the term “gripper finger” may imply that the gripper finger is replaceable or removable and may be used interchangeably with “removable gripper finger” or “replaceable gripper finger.”

FIG. 12 depicts a gripper unit 2000 that provides the capability for quick exchange of gripper fingers, in one embodiment of the invention.

The gripper unit 2000 may include a body 2002 and removable gripper fingers 2004, 2006, 2008. The gripper unit 2000 may be similar to the gripper unit 1114 and may be coupled to the robot arm 1002 and the processing unit 1106. It will be understood that the gripper unit 2000 may be coupled to other units or modules in the laboratory automation system 1104 for performing the intended functions. The body 2002 may be coupled to a gripper finger release assembly 2010 so that the gripper fingers 2004, 2006, 2008 can be quickly exchanged. It is to be understood that the body 2002 may include or couple to other components or structures suitable for performing the intended function of the gripper unit 2000, for example, as a tube gripper, a recapper or a decapper.

In some embodiments, the gripper finger release assembly 2010 may include one or more release elements. The release elements can couple and uncouple the gripper fingers 2004, 2006, 2008 from the body 2002 without demounting or uncoupling the gripper finger release assembly 2010 from the body 2002 and without using special tools. In some embodiments, a sample tube 2012 may be gripped by the removable gripper fingers 2004, 2006, 2008. In one embodiment, the sample tube 2012 may have a cylindrical shape with a circular cross-section. In some embodiments, the sample tube 2012 may have a cap 2014. The cap 2014 may have a cylindrical shape with a circular cross-section and a diameter slightly larger than the diameter of the sample tube 2012 and a length relatively shorter than the length of the sample tube 2012. It will be understood that other shapes and sizes of the sample tube 2012 and the cap 2014 are possible that can be gripped by the gripper unit 2000. Further, other objects such as caps, secondary test tubes, capillaries, pipettes may also be gripped by the gripper unit 2000. In some embodiments, a replaceable jaw may be coupled to one end (gripping end) of each of the gripper fingers 2004, 2006, 2008 for accommodating different types of objects such as sample tubes, caps, capillaries, pipettes, secondary test tubes, etc.

In some embodiments of the invention, each of the gripper fingers 2004, 2006 and 2008 may comprise a cavity so that each of the gripper finger can couple to a release element in the gripper finger release assembly 2010 to enable a quick exchange of the gripper finger.

FIGS. 13A-13C illustrate a release element 2100 according to a first embodiment of the invention.

In some embodiments of the invention, the release element 2100 may be part of the gripper finger release assembly 2010 that may be coupled to the body 2002 of the gripper unit 2000.

As illustrated in FIG. 13A, the release element 2100 may include a connection plate (or plate) 2102, a first sliding element 2104, a second sliding element 2106, a cap 2108 and a spring 2110. Different components of the release element 2100 are further described with reference to FIG. 13B. In one embodiment, the release element 2100 may be coupled to a mounting structure 2112, as illustrated in FIG. 13C. A gripper finger may be coupled to the first sliding element 2104 and to the mounting structure 2112. In some embodiments, the first sliding element 2104, the second sliding element 2106, the cap 2108 and the spring 2110 may have a circular, radial cross-sections. In one embodiment, the release element 2100 may be configured to allow the exchange of each of the gripper fingers 2004, 2006, 2008 without demounting or mounting the gripper finger release assembly 2010 and without the need to use tools.

In some embodiments, the connection plate 2102 may be coupled to the first sliding element 2104 and the second sliding element 2106. The connection plate 2102 may be coupled so that the first and second sliding elements 2104, 2106 may be removed from the connection plate 2102, or they may be integral with the connection plate 2102. As shown in FIG. 13A, the connection plate 2102, the first sliding element 2104, and the second sliding element 2106 may form a U-shape. The connection plate 2102 may be configured so that the first sliding element 2104 and the second sliding element 2106 are aligned and connected so that gripper fingers 2004, 2006, 2008 can be exchanged.

As illustrated in FIG. 13B, the connection plate 2102 may have a rectangular cross-section (viewed from its side) and may have two cavities 2102A, 2102 B. In some embodiments, each of the cavities 2102A, 2102 B may have a circular cross-section and they are configured to accommodate and receive a portion of the first sliding element 2104 and a portion of the second sliding element 2106, respectively. The cavities 2102A, 2102 B may each be of any suitable length.

In one embodiment of the invention, the first sliding element 2104 may be cylindrical in shape with a circular, radial cross-section. The first sliding element 2104 may also have any suitable length (e.g., two or more inches in length). The first sliding element 2104 may also be called a “finger pin” in some embodiments.

The first sliding element 2104 may be configured so that a first end 2104A of the first sliding element 2104 can pass through a cavity in a removable gripper finger (not shown in FIGS. 13A and 13B) and a cavity in the mounting structure 2112 to secure the gripper finger to the mounting structure 2112. A diameter of the first sliding element 2104 including the first end 2104A may be slightly smaller than a diameter of the cavity in the removable gripper finger so that the gripper finger can slide on the first sliding element 2104. A second end 2104B of the first sliding element 2104 can couple to the connection plate 2102 through the cavity 2102B. The diameter of the first sliding element 2104 including the second end 2104B can be slightly smaller than the cavity 2102B so that the first sliding element 2104 can pass through the cavity 2102B. In one embodiment of the invention, the first sliding element 2104 is permanently coupled to the connection plate 2102 via the cavity 2102B.

In one embodiment of the invention, the second sliding element 2106 may also be cylindrical in shape and may have a circular radial cross-section and may be slightly longer than the first sliding element 2104. The second sliding element 2106 may also be called a “push screw” in some embodiments. The second sliding element 2106 may be configured so that a first end 2106A of the second sliding element 2106 is slightly smaller than the rest of the second sliding element 2106 and is configured to couple (temporarily or permanently) to the cap 2108. In some embodiments, the first end 2106A of the second sliding element 2106 and a second end 2108B of the cap 2108 may be threaded.

A second end 2106B of the second sliding element 2106 may be configured so that it can pass through a cavity 2110A in the spring 2110 and couple to the connection plate 2102 through the cavity 2102A. In one embodiment of the invention, the cap 2108 is configured as a counterpart to a cavity (not shown) in the mounting structure 2112 so that the cap 2108 can slide in and out of the cavity in the mounting structure 2112, when a first end 2108A of the cap 2108 is pressed to release or couple a gripper finger to the gripper unit 2000.

In one embodiment, the second sliding element 2106 has a round, axial cross section and can pass through the spring 2110. In one embodiment, the spring 2110 may be in uncompressed state so that the gripper finger release assembly 2010 is in a closed position (e.g., normal position) with a gripper finger coupled to the first sliding element 2104. In the closed position, the spring 2110 may be configured to urge the connection plate 2102 toward the cap 2108 such that the cap 2108 passes through a cavity in the mounting structure 2112 coupled to the body 2002. The spring 2110 may be a compression spring or any suitable biasing element for providing the appropriate force to keep the gripper finger release assembly 2010 in the closed position.

The cap 2108 may be cylindrical in shape with a diameter that exceeds the diameter of the second sliding element. In one embodiment, the cap 2108 may be configured so that when the cap 2108 is pushed or pressed, the cap 2108 slides into a cavity on the mounting structure 2112. Pushing the cap 2108 further enables the first sliding element 2104 to release the gripper finger due to the movement of the connection plate 2102 away from the mounting structure 2112.

A first gripper finger may be secured to the mounting structure 2112 by coupling to the first sliding element 2104. In embodiments of the invention, the first gripper finger may be released by pushing or pressing the cap 2108. The pushing or pressing the cap 2108 pushes the connection plate 2102 away from the mounting structure, thus uncoupling the gripper finger from the first sliding element 2104. After the first gripper finger has been released, a second gripper finger may be coupled to the first sliding element 2104 by keeping the cap 2108 pressed and aligning a cavity in the second gripper finger with the first end 2104A of the first sliding element 2104 and sliding the second gripper finger on to the first sliding element 2104. By releasing the cap 2108 pushes the gripper finger release assembly 2010 in a closed position by enabling the spring 2110 force the connection plate 2102 towards the mounting structure 2112 such that the cap 2108 slides out of the cavity of the mounting structure 2112.

In embodiments of the invention, the cap 2108 defines the space for the movement of the spring 2110 and also prevents the spring 2110 from getting lost.

FIGS. 14A-14B illustrate the gripper finger release assembly in a closed position 2200, in one embodiment of the invention.

As illustrated in FIG. 14A, a cover 2202 may be coupled to the release element 2100 for covering at least some components of the release element 2100. The cover 2202 may be in a first position during the normal operation of the gripper unit and in a second position during the exchange of the gripper fingers. In one embodiment, the cover 2202 may be in a closed position (first position) for the normal operation, as shown in FIG. 14A, and in an upward position (second position) for exchanging the fingers. The cover 2202 further protects the release element 2100 from contamination/pollution and maintains the closed position of the assembly during normal operation. It will be understood that various other configurations of the cover 2202 are possible.

As illustrated in FIG. 14A, cavities 2204, 2206 may be associated with a connection plate 2208 for a second release element configured for exchanging the gripper finger 2008. Similarly, cavities 2210, 2212 may be associated with a cap and a first end of a first sliding element respectively for a third release element configured for exchanging the gripper finger 2004. Note that each release element may have a cover (not shown) which may be in a first position during the normal operation of the gripper unit and in a second position during the exchange of the respective gripper finger.

In the closed position of the gripper finger release assembly, the first sliding element 2104 may pass through a first cavity in the mounting structure 2112 and a cavity in the gripper finger 2006 to secure the gripper finger 2006 to the mounting structure 2112. The cap 2108 may be pushed out from the force of the spring 2110 (not shown in FIG. 14A) through a second cavity in the mounting structure 2112. An internal, cross-sectional view of the gripper finger release assembly in the closed position is shown in FIG. 14B.

In one embodiment, the gripper finger 2006 may be coupled to the first sliding element 2104 through a bushing 2214 or any other suitable component, as illustrated in FIG. 14B. The bushing 2214 may be made of rubber or any such suitable material and may be configured to allow coupling of the gripper finger 2006 to the first sliding element 2104.

FIG. 15 illustrates an inside view of the gripper finger release assembly in an open position 2300, in one embodiment of the invention.

As illustrated in FIG. 15, the first sliding element 2104 may be configured to pass through a cavity 2304 in the gripper finger 2006 and a cavity 2302 in the mounting structure 2112 to secure the gripper finger 2006 to the mounting structure 2112. In order to open the gripper finger release assembly for releasing or exchanging a gripper finger, the cap 2108 may be pressed until the head of the cap 2108 is leveled with a surface of the mounting structure 2112 through a cavity 2306 in the mounting structure 2112. Note that the pressing of the cap 2108 pushes the connection plate 2102 away from the mounting structure 2112 and keeps the spring 2110 in a compressed state. This enables the first sliding element 2104 to slide out of the cavity 2304 in the gripper finger 2006, thus releasing or uncoupling the gripper finger 2006.

In some embodiments, the cavity 2302 may be substituted for a bushing, which may be pressed in the mounting structure 2112.

Referring back to FIG. 14B, as compared to the open position of the gripper finger release assembly, the first sliding element 2104 is pushed out from the cavity 2304 of the gripper finger 2006. This allows the uncoupling of the gripper finger 2006 from the gripper unit. In this position a new gripper finger may be coupled to the first sliding element 2104 by keeping the cap 2108 pressed and by sliding the new gripper finger on the first sliding element 2104 through a cavity in the new gripper finger. Once the new gripper finger is coupled to the first sliding element 2104, the cap 2108 may be released which enables the spring 2110 to uncompress and push the cap 2108 out of the cavity 2306 in the mounting structure 2112 and bring the gripper finger release assembly to a closed or locked position.

Embodiments of the invention provide a method to replace a first gripper finger with a second gripper finger using a release element, for example, the release element 2100.

In a first step of the method, the first gripper finger may be removably coupled to a mounting structure by the release element. The first gripper finger may comprise a first cavity and the mounting structure may comprise a second cavity. The release element may comprise a plate, a first sliding element coupled to the plate and a second sliding element coupled to the plate. The first sliding element may be configured to pass through the first and second cavities to secure the first gripper finger to the mounting structure. Referring back to FIG. 15, the first gripper finger may be removably coupled to the mounting structure 2112 by the release element 2100. For example, the first sliding element 2104 may pass through a first cavity in the first gripper finger (similar to the cavity 2304) and the cavity 2302 in the mounting structure 2112.

In a second step of the method, the first gripper finger may be released by pressing the second sliding element. For example, by pressing the cap 2108 presses the second sliding element 2106, thus enabling the first sliding element 2104 to slide out of the cavities 2304 and 2302 and release the first gripper finger.

In a third step of the method, a third cavity on the second gripper finger may be aligned with the first sliding element after the first gripper finger has been released. For example, the third cavity (similar to the cavity 2304) on the second gripper finger may be aligned with the first sliding element 2104 so that the first sliding element 2104 can easily pass through it.

In a fourth step of the method, the second gripper finger may be removably coupled to the first sliding element by releasing the second sliding element. For example, by releasing the second sliding element 2106 (or the cap 2108) enables the spring 2110 to uncompress and push the second sliding element 2106 (or the cap 2108) out of the cavity 2306 in the mounting structure 2112, thus coupling the second gripper finger to the first sliding element 2104.

Embodiments of the invention provide advantages since no tool is required for exchanging the gripper fingers. The gripper finger release assembly can be unlocked with only one movement by using a small force to overcome the force of the spring. Further, the spring gets no load since bearing of forces is separated from the closing feature. Embodiments of the invention prevent twisting of the gripper fingers relative to the gripper unit due to the inherent configuration of the release element 2100.

FIG. 16 illustrates a release element 2400 in a second embodiment of the invention.

In one embodiment, the release element 2400 may be part of the gripper finger release assembly 2010. The release element 2400 may comprise a post (or a sliding element) 2402 coupled to a plate 2410. The plate 2410 may be a part of or coupled to a mounting structure 2412. In one embodiment, the mounting structure 2412 is part of the body 1116 of the gripper unit 1114.

The post 2402 may be similar to the first sliding element 2104 (as shown in FIGS. 13A-13B) and may have a cylindrical shape with a circular cross-section. The post 2402 may be configured to removably couple to a gripper finger (e.g., one of the gripper fingers 1118) within a gripper finger slot 2408 and further be configured to pass through a cavity in the gripper finger and a cavity in the mounting structure 2412 to secure the gripper finger to the mounting structure 2412. The cavity in the gripper finger may be similar to the cavity 2304 of the gripper finger 2006, as shown in FIG. 15, with a diameter slightly larger than the diameter of the post 2402 so that the post 2402 can pass through the cavity of the gripper finger.

In one embodiment, a lever 2404 may be coupled to the plate 2410 and the post 2402 and configured to control the movement of the post 2402 within the gripper finger slot 2408. In one embodiment, the lever 2404 may be configured to enable the post 2402 to release a first gripper finger coupled to the post 2402 by rotation of the lever 2404. For example, the lever 2404 can be rotated (e.g., by approximately 90 degrees) and pulled away from the gripper finger slot 2408 (e.g., to the right or counterclockwise, in accordance with the illustrative example shown in FIG. 16) to release the first gripper finger. A groove 2406 in the mounting structure 2412 may be configured to accommodate the post 2402 when the post 2402 has been removed from the gripper finger slot 2408.

In one embodiment, rotating the lever 2404 in a second direction (e.g., to the left or clockwise, as shown in the illustrative example of FIG. 16) may slide the post 2402 into the gripper finger slot 2408 so that a second gripper finger may be coupled to the post 2402.

FIGS. 17A-17C illustrate a release element 2500 in a third embodiment of the invention.

In one embodiment, the release element 2500 may be part of the gripper finger release assembly 2010. The release element 2500 may comprise a post (or a sliding element) 2504 coupled to a plate 2506. A gripper finger 2502 may be removably coupled to the post 2504. The plate 2506 may be a part of or coupled to a mounting structure 2514. In one embodiment, the mounting structure 2514 is part of the body 1116 of the gripper unit 1114. A spring 2512 may be coupled to the mounting structure 2514 configured to be in contact with the post 2504.

The post 2402 may be similar to the first sliding element 2104 (as shown in FIGS. 13A-13B) and may have a cylindrical shape with a circular cross-section. The post 2402 may be configured to pass through a cavity in the gripper finger 2502 and a cavity in the mounting structure 2514 to secure the gripper finger 2502 to the mounting structure 2514. The cavity in the gripper finger 2502 may be similar to the cavity 2304 of the gripper finger 2006, as shown in FIG. 15, with a diameter slightly larger than the diameter of the post 2504 so that the post 2504 can pass through the cavity of the gripper finger 2502.

In one embodiment, the plate 2506 is configured as a rotating plate that can be pivoted about an axis defined by a pin 2508 coupled to the plate 2506. The pin 2508 may also be coupled to the mounting structure 2514 and configured to enable the rotation of the plate 2506 in a clockwise or a counter clock wise direction relative to the pin 2508, as discussed with reference to FIGS. 17B-17C.

As illustrated in FIGS. 17B-17C, in one embodiment, the plate 2506 may be circular in shape with an opening 2516 relatively larger than the diameter of the post 2504 in order to allow the post 2504 pass through the opening 2516 when the plate 2506 is rotated. It will be understood that any configuration of the plate 2506 and the opening 2516 is possible in order to allow the post 2504 to pass though the opening 2516.

FIG. 17B illustrates a closed position of the plate 2506, in which the post 2504 is confined in a cavity 2510 behind the rotating plate 2506. In this position the gripper finger 2502 may be coupled to the post 2504 and the spring 2512 may be in a compressed state.

FIG. 17C illustrates an open position of the plate 2506, in which the post 2504 is released through the opening 2516 of the rotating plate 2506. The spring 2512 urges the post 2504 towards the opening 2516, thus allowing the post 2504 to be extract from the cavity 2510. When the post 2504 is extracted, the gripper finger 2502 can be removed and replaced with another gripper finger.

As discussed above, a first gripper finger comprising a first cavity may be removably coupled to a mounting structure comprising a second cavity by a release element. The release element may be the release element 2100, release element 2400 or the release element 2500. The release element may comprise a plate and a first sliding element coupled to the plate, and wherein the first sliding element is configured to pass through the first and second cavities to secure the first gripper finger to the mounting structure. The first gripper finger may be released by enabling the first sliding element to slide out of the first and second cavities. After the first gripper finger has been released, a third cavity on a second gripper finger is aligned with the first sliding element to removably couple the second gripper finger to the first sliding element.

Embodiments of the invention provide quick one-handed exchange of gripper fingers without the need of tools or without demounting or mounting of the gripper finger release assembly from the gripper unit. Thus, embodiments allow quick exchange of gripper fingers, for example, to change the function of the gripper unit, e.g., as a tube gripper, recapper or a decapper.

In this section, a number of gripper unit embodiments using removable specimen gripper fingers are described in detail. It is understood that any features from these embodiments may be combined with any of the previously described sensing gripper unit embodiments described above, as well as strip off element and/or fill level detection systems and methods described below, without departing from the scope of the invention. For example, in one embodiment, the system includes a gripper unit for gripping the specimen container. The gripper unit comprises a mounting structure, a plurality of gripper fingers, a plurality of release elements respectively coupling the gripper fingers in the plurality of gripper fingers to the mounting structure, and a sensing device. The sensing device is configured to produce an output. The system further includes a processor, where the processor is configured to determine a dimension or a weight of the specimen container based on the output. As noted above, the sensing device may be a load cell or a potentiometer.

III. Chute Arrangement with Strip-Off Element

Another embodiment of the invention provides systems and methods for a chute arrangement comprising an element for objects, such as, test tubes, caps, etc. released by a gripper unit such that the released objects may be collected in a container. Embodiments may be used for any objects that need to be collected in a container, such as specimen containers, secondary tubes that need not be stored, caps, capillary waste, pipette waste, etc.

A gripper unit according to an embodiment of the invention may utilize plurality of gripper fingers to grip an object. In embodiments of the invention, at least one gripper finger in the plurality of gripper fingers may separate (e.g., strip off) from a sticky object so that the at least one gripper finger is not stuck to the object and the object is released from the gripper finger. An element can be used to surround the object to restrain (hold back) the object as the gripper fingers release the object.

FIG. 18A illustrates a typical gripper unit operable to grip a specimen container.

Typically, a gripper unit 2650 may be operable to grip a specimen container 2654 using gripper fingers 2652 to discard the specimen container 2654 into a waste container. The specimen container 2654 may be a test tube containing patient samples. Under normal conditions, the gripper unit 2650 may release the specimen container 2654 by opening the gripper fingers 2652. However, in some cases, a substance 2656 may be stuck to an outside surface of the specimen container 2654. The substance 2656 may be deposited due to contamination from aliquotting or glue from a label stuck on the surface of the specimen container 2654. Due to the presence of the substance 2656, the gripper fingers 2652 may get stuck to the specimen container 2654 during the process of discarding the specimen container 2654. As a result, when the gripper unit 2650 opens its gripper fingers 2652 to release the specimen container 2654, the specimen container 2654 may be left dangling because it is attached to the gripper finger. This may increase the processing time to discard the specimen containers as human intervention may be required to remove the stuck specimen container 2654. Further, contamination may be transported by the gripper fingers 2652 to other specimen containers, thus, further spreading the contamination.

FIG. 18B illustrates a prior art robotic gripper 2660 that may be used as a strip-off element for caps.

The robotic gripper 2660 comprises a strip-off element 2662 for caps using gripper fingers 2664. A similar robotic gripper is used in Beckman Automate™ 2500 series as a decapper for decapping or removing caps from specimen containers, such as, sample tubes. In such a system, if there is contamination on a sample tube, the contamination may be transferred to the body of the strip-off element 2660 (e.g., the cylinder). Since the strip-off element 2662 is attached to the body of the robotic gripper 2660, it may not be easily cleaned and the contamination may be transferred to other specimen containers.

Another embodiment of the invention provides for an element that is detached from the gripper unit, thus, can be easily replaced or removed for cleaning, etc. The element may be part of a chute arrangement that can be mounted right above a waste container so the contamination does not get transferred to other components of the automation system. Embodiments may be used for any object that needs to be collected in a container, such as discarded specimen samples (e.g., waste tubes), secondary tubes that need not be stored, capillary waste, pipette tip waste or test tube cap waste used in various modules of a medical laboratory system (e.g., de and re-capper module, serum indices module, aliquoter module).

In one embodiment of the invention, the robot arm 1002 may be operable to grip a specimen container (e.g., a sample tube) using the gripper unit 1114 from a specimen carrier (e.g., a tube rack) and drop it through the chute arrangement 1122 into a waste container that may be part of the container unit 1128. This is further explained with reference to FIG. 19.

FIG. 19 illustrates certain elements of an exemplary system 3000 comprising a chute arrangement, in one embodiment of the invention.

The exemplary system 3000 may include the robot arm 1002 coupled to a gripper unit 3002 including gripper fingers 3004. The gripper unit 3002 may grip an object such as a specimen container 3014 using the gripper fingers 3004 and may discard the specimen container 3014 into a waste container 3016. The waste container 3016 may be part of the container unit 1128. Further, in some embodiments, the gripper fingers 3004 may be removably coupled to the body of the gripper unit 3004 such that one or more of the gripper fingers 3004 may be exchanged with a new gripper finger using one of the release elements (e.g., release elements 2100, 2400, 2500) that may be coupled to the body of the gripper unit 3002.

In one embodiment of the invention, a chute arrangement 3012 may include a top chute 3006 in the form of an element and a bottom chute 3010 coupled to the top chute 3006 through an optional adapter unit 3008. In another embodiment, the chute arrangement 3012 may include a single chute to enable the passing of an object towards the waste container 3016. For example, the single chute may be a combination or some alternative form of the top chute 3006 and the bottom chute 3010. In one embodiment, the gripper unit 3002 may be similar to the gripper unit 1114 and may be communicatively coupled to the processing unit 1106. The processor 1108 may control the gripper unit 3002 using code stored in the memory 1110. In some embodiments, the processor 1108 may further be able to determine characteristics associated with the specimen container 3014 and/or the specimen inside the specimen container 3014 based on outputs from one or more sensors (e.g., sensor unit 1120) coupled to the gripper unit 3002.

In some embodiments, a sensor unit 3018 may be in proximity to the chute arrangement 3012, as shown in FIG. 19. The sensor unit 3018 may include one or more sensors and may be part of the sensor unit 1120. For example, the sensor unit 3018 may include an ultrasonic sensor, an optical sensor, a motion sensor or any such suitable sensor. In some embodiments, the sensor unit 3018 may be configured to detect the presence of an object, e.g., the specimen container 3014 passing through the chute arrangement 3012 and generate an output. In some embodiments, detection of a falling object through the chute arrangement 3012 may be used to keep a count of the number of objects (e.g., tubes, caps, etc.) that can be collected in the waste container 3016 by the processor 1108 based on the output from the sensor unit 3018. In one embodiment, the sensor unit 3018 may be configured to detect different fill levels of objects in the waste container 3016.

The gripper unit 3002 may be configured to grip the specimen container 3014 using the gripper fingers 3004. In embodiments of the invention, the chute arrangement 3012 helps direct the specimen container 3014 into the waste container 3016, when the specimen container 3014 is released by the gripper fingers 3004. The chute arrangement 3012 may be configured to allow un-gripped objects to fall through the chute by means of gravity. If the specimen container 3014 is not sticky (i.e., no substance 1056), the specimen container 3014 may fall into the waste container 3016 when it is released by the gripper fingers 3004. However, as explained above, the specimen container 3014 may stick to the gripper fingers 3004. In embodiments of the invention, the top chute 3006 can be an element and can separate the specimen container 3014 from the gripper fingers 3004, when the gripper fingers 3004 move outwardly to release the specimen container 3014. The top chute 3006 may restrain the specimen container 3014 from moving with the gripper fingers 3004 as they move outwardly away from the specimen container 3014. This allows the specimen container 3014 to separate from the gripper fingers 3004 so that it can pass down through the chute arrangement 3012.

The adapter unit 3008 may be configured as a spacer unit to provide a height adjustment for mounting the chute arrangement 3012 on a platform. One end of the adapter unit 3008 may be coupled to the top chute 3006 and another end of the adapter unit 3008 may be coupled to the bottom chute 3010. The adapter unit 3008, in combination with the top chute 3006, may be configured to have a length that is equal to or greater than the length of the specimen container 3014 such that no part of the specimen container 3014 can stick to gripper fingers 3004 beyond the chute. In case a cap of the specimen container 3014 is partially or entirely removed from the specimen container 3014 before the specimen container 3014 is released from the gripper fingers 3004, a potential splash of the sample specimen (e.g., fluid) can be confined by the top chute 3006 and/or the adapter unit 3008. The chute arrangement 3012 may be able to accommodate specimen containers of any suitable length so that the specimen container does not interrupt the acoustic, light, or other signal used for detecting the falling specimen container, when the specimen container is in the grasp of the gripper unit 3002. In one embodiment, the combined length of the top chute 3006 and the adapter unit 3008 can be adjusted to accommodate lengths of different objects that are intended to be passing through the chute arrangement 3012.

The bottom chute 3010 may be configured to provide multiple functions. The bottom chute 3010 may include a mechanism for mounting on a platform to provide support or stability to the chute arrangement 3012. For example, one end of the bottom chute 3010 may comprise mounting tabs for mounting on a platform and another end of the bottom chute 3010 may couple to the adapter unit 3008 or directly to the top chute 3006. In one embodiment, the bottom chute 3010 may be configured to be in a close proximity of the sensor unit 3018 so that the sensor unit 3018 can detect a falling object passing through the bottom chute 3010. For example, an opening on the bottom chute 3010 may be in a line of sight of the sensor unit 3018 so that an ultrasonic signal transmitted by the sensor unit 3018 can reflect from a surface of an object passing through the bottom chute 3010 and bounce back to the sensor unit 3018. The sensor unit 3018 may be communicatively coupled to the processing unit 1106 so that a count of the falling objects can be stored and/or updated in the memory 1110 by the processor 1108. In one embodiment, when the sensor unit 3018 does not detect an object passing through the bottom chute 3010, a beam emitted by the sensor unit 3018 may get deflected downwards into the waste container 3016 by an inclined surface of the bottom chute 3010 and may help determine a fill level of the waste container 3016.

In FIG. 19, the bottom chute 3010 has wider dimensions than the top chute 3006. The increased size of the bottom chute 3010, in conjunction with the sensor unit 3018, can provide for the capability of detecting falling objects. However, it is to be noted that the bottom chute 3010 may have any suitable design as long as it can interface with the top chute 3006, with or without the adapter unit 3008.

In embodiments of the invention, the top chute 3006 enables the waste tube 3014 to strip off from the gripper fingers 3004, as further explained with reference to FIGS. 20A-20B.

FIGS. 20A-20B are close up, perspective views of a top chute in the form of an element.

As illustrated in FIG. 20A, the top chute 3006 includes a plurality of slots 3102. In one embodiment, each of the plurality of slots is parallel to a longitudinal axis of the top chute 3006. In embodiments of the invention, the gripper fingers 3004 may generally enter the plurality of slots 3102 from above for at least partially inserting the specimen container 3014 gripped by at least two of the gripper fingers 3004. In one embodiment, the gripper fingers 3004 may open laterally to release the gripped specimen container 3014. A geometric dimension of each of the plurality of slots 3102 may be smaller than an overall length, width or height of the specimen container 3014 such that the specimen container 3014 is unable to pass through the slots 3102 when released by the gripper fingers 3004. In one embodiment, the geometric dimension of each of the plurality of slots may be a width of the slot so that each of the gripper fingers 3004 may pass through the slot but not the object. Under normal conditions, the specimen container 3014 may drop down the chute arrangement 3012 into the waste container 3016 when the specimen container 3014 is released from the gripper fingers 3004, as shown in FIG. 19. However, if there is contamination on the specimen container 3014, the specimen container 3014 may stick to the gripper fingers 3004. Embodiments provide a stripping feature in the top chute 3006 such that the gripper fingers 3004 can be moved by the gripper unit 3002 to extend outwardly through the slots 3102 so that the specimen container 3014 can be released and separated from the gripper fingers.

FIG. 20B illustrates open gripper fingers 3004 that have opened outwardly outside the slots 3102 of the top chute 3006. The gripper fingers 3004 do not touch the sample container 3014 and are completely separated from it.

The slots 3102 may be configured such that the gripper fingers 3004 may pass through the slots 3102. If the specimen container 3014 sticks to the gripper fingers 3004 due to some contamination (e.g., substance 2656) during the movement of the opening of the gripper fingers 3004, the element of the top chute 3006 retains the specimen container 3014 within it so that the specimen container 3014 is released from the gripper fingers 3004 and passes down through the chute arrangement 3012. Because slots 3102 are smaller in dimensions (e.g., narrower) than the specimen container 3014, the specimen container 3014 does not pass through the slots 3102 when the gripper fingers 3004 pass through the slots and is restrained by the element. The element can be made of a material sufficiently strong to restrain the specimen container 3014 if the specimen container 3014 sticks to the gripper fingers 3004 due to contamination on the specimen container 3014. Some non-limiting examples of the material for the element are metal (e.g., steel or aluminum), plastic, Teflon, etc. Stabilizing bars 3104 on the surface of the top chute 3006 may help provide further stabilization.

The specimen container 3014 may be collected in a container, e.g., the waste container 3016 or for further processing. The substance 2656 may get transported with the specimen container 3014 into the waste container 3016 instead of sticking to the gripper fingers 3004. This may avoid having contamination from the substance 2656 transferred to the other objects that may come in contact with the gripper fingers 3004.

FIG. 21 illustrates a top chute arrangement with a square shaped radial cross-section, or a square shaped profile, according to one embodiment of the invention.

A top chute arrangement 3200 may comprise an element 3202 and an adapter unit 3204, both with a square shaped profile. The element 3202 may comprise an element body 3202A comprising a central axial bore 3202B, a first end 3202C and a second end 3202D. For example, the gripper unit 3002 may insert the specimen container 3014 held by the gripper fingers 3004 into the element 3202 from top for discarding it. In various embodiments of the invention, the element 3202 may be configured to have dimensions that may allow different types of objects (e.g., different types of tubes, caps, etc.) to be surrounded by the element body 3202A so that the element body 3202A can restrain the object when the object is released by the gripper fingers. The top chute arrangement 3200 may have any suitable profile that would allow a correct alignment of the element 3202 and the gripper unit 3002 to allow the gripper fingers 3004 to properly enter the plurality of slots 3206. In one embodiment, the top chute arrangement 3200 is part of the chute arrangement 1122.

As shown in FIG. 21, the element body 3202A has a square shaped profile. In one embodiment, the element body 3202A may comprise four walls where each wall may comprise a slot. In some embodiments, the element body 3202A may comprise a plurality of stabilizing bars 3202E for providing stabilization or support to the element 3202. As illustrated in FIG. 21, there is one stabilizing bar on each side of the slot, which runs longitudinally along the element body 3202A from the first end 3202C to the second end 3202D.

In one embodiment, the second end 3202D of the element body 3202A may have slightly larger dimensions than the rest of the element body 3202A. In one embodiment, the second end 3202D may be configured to support the coupling of the stabilizing bars 3202E to the element body 3202 A. The stabilizing bars 3202 may be integrally formed with the main body of the element, or could be separate parts that are attached to the main body of the element. The second end 3202D may further be configured to couple to one end of the adapter unit 3204. The element body 3202A may comprise of a material with sufficient strength to restrain a specimen container from moving with the gripper fingers when the gripper fingers are moving away from the specimen container through the slots 3206. The number of slots 3206 may be same as the number of gripper fingers and configured in shape and size such that the gripper fingers may pass through the slots 3206 but the specimen container stays confined within the element 3202. In one embodiment, the slots 3206 are parallel to a longitudinal axis of the central axial bore 3202B.

In one embodiment, each slot in the plurality of slots 3206 may have a rectangular cross-section and may have an open end 3206A and a closed end 3206B. The open end 3206A may coincide with the first end 3202C of the element body 3202A to enable the gripper fingers to insert a gripped object into the central axial bore 3202B from above. The closed end 3206B may be at a distance approximately half way down the entire length of the element body 3202A. In some embodiments, the length and width of each slot may depend upon a number of factors such as the dimensions (e.g., length of the element, width of each wall, etc.) of the element body 3202, the dimensions (e.g., length, width, thickness, etc.) of the gripper finger passing through each slot, the dimensions of each object that may be surrounded by the element body 3202A for dropping through the top chute arrangement 3200, material of the element 3202, etc.

In one embodiment, the adapter unit 3204 has a square shaped profile. However, any suitable shape is possible. The square shaped profile of the adapter unit 3204 may provide for easy alignment with the element 3202. The adapter unit 3204 or other portion of the element 3202 having a square cross-sectional profile can be used to ensure that each time the top chute arrangement 3200 is installed, the plurality of slots 3206 are positioned to receive the gripper fingers. The square shaped profile of the element 3202 provides a benefit over a cylindrical shape since a cylindrical shaped chute may be rotated when replaced such that the gripper fingers are not aligned with the slots. In some embodiments, a cylindrical shape profile with specific alignment features may be used. In one embodiment, these features are preferably located at the second end 3202D of the element body 3202A and may e.g. interface with the adapter unit 3204 in such a way that an unintentional rotation or misplacement of the element 3202 that would lead to a mis-alignment of the slots 3206 in relation to the gripper fingers 3004, is avoided.

In one embodiment, the adapter unit 3204 is part of the element 3202. The adapter unit 3204 may further be configured to couple to a bottom chute for forming a chute arrangement that may be used to drop off waste objects into a waste container, e.g., the waste container 3016. For example, referring back to FIG. 19, one end of the bottom chute 3010 which connects to the adapter unit 3008 may be configured to have a square shaped profile so that the bottom chute 3010 may be coupled to the adapter unit 3204 for forming a chute arrangement. Further, the chute arrangement may be coupled to a platform, as described with reference to FIG. 22.

FIG. 22 illustrates a perspective view of the placement of a chute arrangement 3300 according to one embodiment of the invention.

As illustrated in FIG. 22, a top chute 3302 is coupled to a bottom chute 3306 via an adapter unit 3304. In one embodiment, the top chute 3302 may be attached directly to the bottom chute 3306 without the adapter unit 3304 or any other intermediary unit. In another embodiment, the adapter unit 3304 may be a part of the bottom chute 3306. Top chute 3302 may be easily removed or replaced for cleaning or other maintenance.

In one embodiment of the invention, the top chute 3302 may have a square shaped profile similar to the top chute 3202 of FIG. 21. Similarly, the adapter unit 3304 may have a square shaped profile similar to the adapter unit 3204 that provides an easy alignment with the top chute 3302. Further, the adapter unit 3304 or other portion of the top chute 3302 may be inserted into an opening, such as an opening in a deck 3308, for support or stability. The bottom chute 3306 may comprise a plurality of mounting tabs for mounting on a deckbase 3310. However, it is to be noted that any mechanism may be used to connect the bottom chute 3306 to the deckbase 3310 or any other stabilizing platform. In one embodiment, the top chute 3302 may be attached directly to the bottom chute 3306 without the optional adapter unit 3304 or any other intermediary unit. In another embodiment, the adapter unit 3304 may be a part of the bottom chute 3306. The adapter unit 3304 may have a profile that provides an easy alignment with the top chute 3302 (e.g., square shaped or cylindrical profile to match with the top chute 3302).

In one embodiment, the deck 3308 and the deckbase 3310 are part of the laboratory automation system 1104 (e.g., in a storage unit). In one embodiment, the deck 3308 may hold a plurality of specimen carrier racks holding a plurality of specimen carriers carrying multiple specimen containers. In some embodiments, the deck 3308 may hold other means of supplying waste objects through the chute arrangement 3300.

In one embodiment, the adapter unit 3304 may be configured to compensate for the distance between the top chute 3302 and the bottom chute 3306 that results from the presence of the deck base 3310. In some embodiments, the bottom chute 3306 is in close proximity to an ultrasonic sensor 3312 such that the ultrasonic signals emitted from the ultrasonic sensor 3312 are directed towards an opening or side hole in the bottom chute 3306 to detect an object passing through the chute arrangement 3300. In one embodiment, an optical sensor may be used in place of the ultrasonic sensor 3312 for short range detection of the passing objects. The optical sensor may be mounted on the deck base 3310 such that an object falling through the chute arrangement 3300 is in its line of sight. The optical sensor may detect change in light when a sample container passes through the chute arrangement 3300. In some embodiments, the optical sensor may be implemented as a light barrier or a light curtain comprising multiple light barriers in parallel. The ultrasonic sensor and/or the optical sensor may be part of the sensor unit 1120. The chute arrangement 3300 may be part of a specimen output system, as described with reference to FIG. 23.

FIG. 23 illustrates overview of an exemplary specimen output system according to one embodiment of the invention.

In one embodiment, a specimen output system 3400 may be used in medical laboratory systems where specimen containers may need to be discarded, e.g., when the storage time for the specimen container has expired. The specimen container may be a test tube containing material for medical analysis, such as blood, serum, plasma, etc. An output robot 3402 may be used to transport the specimen containers from various areas of a laboratory system, such as input, distribution, centrifuge, decapper, aliquotter, output, analyzer, sorting, recapping, and secondary tube lift areas. The specimen containers may be stored in a single tube carrier rack 3404. A plurality of such racks may be placed in the deck 3308. The output robot 3402 may comprise a gripper unit (e.g., the gripper unit 3002) that may be used to automatically lift a tube from the single tube carrier rack 3404 for discarding into a waste container 3406. Even though the exemplary system 3400 illustrates a test tube rack, specimen containers may be picked up from any handling system, such as a track system or via any test tube supply mechanism.

In one embodiment, the waste container 3406 may include a height 3408, length 3410 and a width 3412 that may be used to determine a fill capacity of the waste container 3406. For example, the height 3408, length 3410 and the width 3412 and any other geometric information related to the waste container 3416 may be stored in the memory 1110 of the processing unit 1106 that may be used by the processor 1108 in combination with other information, such as relating to the waste objects, to determine a fill capacity of the waste container 3406.

Embodiments may be used to help the specimen container pass through a chute arrangement into the waste container 3406 when released by the gripper unit (not shown). In one embodiment, the chute arrangement includes one or more of the top chute 3302, adapter unit 3304 and the bottom chute 3306. The bottom chute 3306 may be mounted on the deckbase 3310 to provide support or stability (as shown in FIG. 22). The adapter unit 3304 may be configured to compensate for the distance between the top chute 3302 and the bottom chute 3306 caused by the deck base 3310. Further, it will be understood that other feeders or supply mechanisms may be used to feed discarded objects through the chute arrangement 3012. For examples, bowl feeders or step feeders may be used to feed individual objects such as caps through the chute arrangement 3012 directed towards the waste container 3406.

Embodiments provide for a number of advantages. For example, by not attaching the waste container 3406 to the chute arrangement or the deckbase 3310, the waste container 3406 may be removed for emptying or replaced with another container.

In some embodiments, the specimen output system 3400 may be part of the laboratory automation system 1104. The output robot 3402 may utilize the robot arm 1002 for gripping an object using the gripper unit 1114 from the single tube carrier rack 3404 and dropping it into the waste container 3406 through the chute arrangement comprising one or more of the top chute 3302, adapter unit 3304 and the bottom chute 3306. In one embodiment, the processing unit 1106 may be in communication with the output robot 3402 to control the output robot 3402 to start and stop the specimen container discarding process.

FIG. 24 illustrates a flow chart for a method of releasing an object through a chute arrangement, in one embodiment of the invention.

In step 3502, an object is gripped using a plurality of gripper fingers in a gripper unit. Referring back to FIG. 19, the gripper unit 3002 may grip the specimen container 3014 using the gripper fingers 3004 (e.g., from the single tube carrier rack 3404 as shown in FIG. 23) for discarding it into the waste container 3016. The gripper unit 3002 may be part of the output robot 3402.

In step 3504, the object is inserted into a chute arrangement using the gripper unit. For example, the gripper unit 3002 may insert the specimen container 3014 into the chute arrangement 3012. The chute arrangement 3012 may comprise the top chute 3006 in the form of an element and the bottom chute 3010 coupled to the top chute 3006 through the optional adapter unit 3008. As shown in FIGS. 20A-20B, the specimen container 3014 may be inserted into the top chute 3006 from above by the gripper unit 3002 using the gripper fingers 3004.

In step 3506, the object is released by the plurality of gripper fingers by causing the gripper fingers to extend outward while the object is within an element of the chute arrangement. As shown in FIG. 20B, the specimen container 3014 may be released by the gripper fingers 3004 by causing the gripper fingers 3004 to extend outward while the specimen container 3014 is within the element 3006 of the chute arrangement 3012. In embodiments of the invention, the element 3006 helps separate the specimen container 3014 from the gripper fingers 3004, when the gripper fingers 3004 release the specimen container 3014 and pass through the plurality of slots 3102.

In step 3508, the object passes through the chute arrangement into a waste container placed under the chute arrangement. As shown in FIG. 19, the specimen container 3014 passes through the chute arrangement 3012 into the waste container 3016 when released by the gripper fingers 3004. The waste container 3016 is not attached to the chute arrangement 3012, thus can be easily replaced or emptied as needed.

IV. Container Fill Level Detection

Referring back to FIG. 2, the gripper unit 1114 may grip a waste object using the gripper fingers 1118 and drop it through the chute arrangement 1122 for discarding it into a waste container that may be part of the container unit 1128. In another embodiment, the gripper unit 1114 may grip a consumable object using the gripper fingers 1118 from a consumable container that may be part of the container unit 1128 and transport it to another work unit or module in the laboratory automation system 1104 for further processing. In one embodiment, the container unit 1128 may include one or more waste containers to collect or store disposable or waste objects such as test tubes, test tube caps, capillaries, secondary test tubes, pipettes etc.

Referring back to FIG. 19, the gripper unit 3002 may be configured to grip objects, such as specimen containers, caps, etc., using gripper fingers 3004 to automatically discard into the waste container 3016. In embodiments of the invention, the waste container 3016 may be configured to collect the objects dropped through the chute arrangement 3012, the feeder unit 1130 or via any other suitable mechanism. The sensor unit 3018 may be configured to detect an object, e.g., the specimen container 3014, passing through the chute arrangement 3012 and provide a corresponding output to the processor 1108 relating to the presence of the object through the chute arrangement 3012. The sensor unit 3018 may also be configured to detect a fill level of the waste container 3016 and provide a corresponding output to the processor 1108 for generating an estimate of the number of objects that can further fit in the waste container 3016.

In one embodiment of the invention, a notification message may be generated including information about the fill level of the waste container 3016. For example, the notification message may include if the waste container 3016 is quarter full, half full, sixty percent full, three quarters full, nearly full, full or any other predetermined fill level. This information may help an operator (e.g., the operator 1102) to determine if the waste container 3016 needs to be emptied or replaced with another waste container.

FIG. 25 illustrates an ultrasonic sensor arrangement 4200 in accordance with embodiments of the invention.

An ultrasonic sensor 4202 may be configured to be in close proximity of a deflector chute 4204 in one embodiment of the invention. The deflector chute and the ultrasonic sensor arrangement serve more than one purpose in embodiments of the invention. The ultrasonic sensor 4202 may be configured to detect presence of an object passing through the deflector chute 4204. The object may be any object that needs to be collected in a container, such as discarded specimen samples (e.g., a waste tube 4206), capillary waste, pipette tip waste or test tube cap waste used in various modules of a medical laboratory system (e.g., de and re-capper module, serum indices module, aliquoter module).

In one embodiment, the deflector chute 4204 is similar to the bottom chute 3010 of the chute arrangement 3012 (in FIG. 19). In this specification, the terms deflector chute and the bottom chute may be used interchangeably. The deflector chute 4204 may have an opening or a hole 4204A on its side facing an opening 4202A of the ultrasonic sensor unit 4202 for the ultrasonic sensor unit 4202 to send and receive ultrasonic waves through the opening 4204A. The deflector chute 4204 may be configured to couple to a top chute (e.g., the top chute 3006) or an optional adapter unit (e.g., the adapter unit 3010) through an opening 4204B. In some embodiments, the deflector chute 4204 may be integrated with a top chute and/or an optional adapter unit to form a single chute. The deflector chute 4204 may also have a deflector surface 4202C to deflect an ultrasound wave or a signal towards a container 4208 to detect a fill level of the container 4208.

In some embodiments, the ultrasonic sensor 4202 may be configured as a transceiver to transmit and receive ultrasound waves. The ultrasonic sensor 4202 may be communicatively coupled to a micro-controller or a processor (e.g., the processor 1108) to provide the detected information. For example, a transducer in the ultrasonic sensor 4202 may be configured to transmit ultrasonic waves in a certain frequency range from the opening 4202A. When an ultrasonic beam 4210 is emitted from the ultrasonic sensor 4202, if no passing object close to the opening 4202A interrupts the ultrasonic beam 4210, the ultrasonic beam 4210 may be downward reflected towards the container 4208 by the inclined deflector surface 4204C of the deflector chute 4204. The beam 4210 may further get reflected from the surface of the container 4208 or from the objects within the container 4208. The reflected beam 4210 may travel to the deflector surface 4204C and may be directed towards the opening 4202A of the ultrasonic sensor 4202. The ultrasonic sensor 4202 can detect the reflected beam 4210 and generate a first output. In one embodiment, the first output may be in the form of a constant signal with varying amplitude depending on the fill level of the container 4208. In one embodiment, the reflected ultrasonic signal may be amplified by an amplifier in the ultrasonic sensor 4202 before transmitting it to the processor 1108. The processor 1108 may be configured to determine a fill level of the container 4208 based on the first output. However, measurements made by the processor 1108 may not be precise in some cases, for example, when there are fewer objects (e.g., less than ten) in the container 4208.

When an object such as the waste tube 4206 passes in front of the opening 4202A, the emitted beam 4210 gets interrupted and sent back to the ultrasonic sensor 4202. Another transducer in the ultrasonic sensor 4202 may receive the reflected beam 4210 and may generate a second output to indicate a passing object. For example, a short pulsed signal may be generated by the ultrasonic sensor 4202 indicating a passing object. The processor 1108 may be configured to increment a counter based on the second output every time a passing object is detected by the ultrasonic sensor 4202. However, there may be possible errors made during counting, for example, an object may be counted more than once or not counted at all during the passing to the container 4208. If the beam 4210 is not interrupted by a falling object, the beam 4210 is deflected downwards by the deflector surface 4204C of the bottom chute 4204.

A dead zone may be a zone close to the ultrasonic sensor 4202 in which objects cannot be detected because they deflect the wave back before the receiver of the ultrasonic sensor 4204 is operational. An active zone may indicate where the ultrasonic waves may be reflected back to the ultrasonic sensor 4202 for measuring the fill level of the container 4208. The ultrasonic wave would have deflected downwards from the deflector surface 4204C of the bottom chute 4204 if the beam 4210 was not interrupted by the falling waste tube 4206. Thus, embodiments may be used to detect falling objects passing through the dead zone of the ultrasonic sensor 4202 closer to the sensor face and also to detect the fill level of a container that may be far away from the ultrasonic sensor.

Embodiments utilize ultrasonic sensors based on the properties of acoustic waves; however, any sensor unit capable of detecting reflected signals or otherwise detecting falling objects may be used. The ultrasonic sensor is advantageous as it provides continuous monitoring of the reflected signal and additionally avoids unwanted reflections that may occur with other types of sensor units. An exemplary ultrasonic sensor 4202 available in the market is Microsonic SICK UM30-213118, having a typical ultrasonic frequency of 200 kHz and a sensing range of 200-2000 mm.

In some embodiments, a sensor unit may comprise two ultrasonic sensors for more precise detection or higher sensitivity. For example, a short range sensor may be used to detect a falling object and a long range sensor may be used to detect the fill level of the container.

FIG. 26 illustrates an exemplary ultrasonic sensor arrangement 4300 using two ultrasonic sensors, in one embodiment of the invention.

A chute arrangement 4302 may be configured to release a sample container 4304 into a waste container (e.g., the container 3016) positioned underneath a platform such as the deckbase 3310 through an opening 4310. The output robot 3402 may grasp the sample container 4304 from a rack or any such sample handling system for discarding it into the waste container through the chute arrangement 4302. A horizontally oriented short range ultrasonic sensor 4306 may be configured to detect falling of the sample container 4304 into the waste container through the opening 4310. A vertically oriented long range ultrasonic sensor 4308 may be configured to detect the filling level of the waste container where the sample container 4304 may be collected. For example, the long range ultrasonic sensor 4308 may emit an ultrasonic beam towards the waste container through an opening 4312 in the deckbase 3310 to detect the fill level of the waste container. The ultrasonic beam may get reflected from an object in the waste container or a surface of the waste container and received by the long range ultrasonic sensor 4308.

Having two separate transceivers provides high sensitivity for individual functions, since in some cases, a single ultrasonic sensor may not have suitable sensitivity for both long range and short range functions. In one embodiment, the frequency used for the short range ultrasonic sensor 2404 is in the range of, e.g., 300-500 kHz, such as 400 kHz and the frequency used for the long range ultrasonic sensor 2406 is in the range of, e.g., 100 to 300 kHz, such as 200 kHz.

FIG. 27 illustrates an exemplary sensor arrangement 4400 using one ultrasonic sensor and one optical sensor, in one embodiment.

In some embodiments, an optical sensor 4402 may be used in place of the ultrasonic sensor 4306 for short range detection of the passing objects. The optical sensor 4402 may be mounted on the deckbase 3310 near the chute arrangement 4302 such that an object falling through the chute arrangement 4302 is in its line of sight. The optical sensor 4402 may be configured to detect a change in light when a sample container passes through the chute arrangement 4302. In some embodiments, the optical sensor 4402 may be implemented as a light barrier or a light curtain comprising multiple light barriers in parallel.

In some embodiments, a fill level of a waste container (e.g., the container 4208) may be determined using the sensor unit. As the objects are dropped in the waste container, due to uneven geometries of the objects such as tubes, the container may not be filled optimally and uneven stacking of the objects may lead to heap building in the container. Even though a fill level detected by the sensor unit may indicate a maximum fill level due to the heap, a counter value that is used to keep track of dropped objects may indicate that there may still be space left in the container. Embodiments of the invention provide a method to reduce the effect of a possible error made in counting and a possible error made in measuring a fill level in the container by using both of the values and weighting the values to determine a fill level. The values may weighted differently as the objects fill the container. A method to determine a fill level of a waste container for disposable objects, such as test tubes, test tube caps, pipettes and capillaries is described below with reference to FIG. 28 and FIGS. 29A-29C.

FIG. 28 illustrates a method 4500 for detecting the fill level of a container in one embodiment.

In step 4502, a maximum fill level “H” of a container may be determined. In one embodiment, the maximum fill level may be determined by optimally (or non-optimally) filling a container to its maximum capacity with objects with one or more known geometric dimensions. Referring back to FIG. 23, a maximum fill level “H” the container 3406 may be determined based on the height 3408, length 3410 and the width 3412 of the container 3406 as well as one or more known geometric dimensions of the object. In one embodiment, the geometric dimensions of the object may be determined as discussed previously with reference to FIG. 3. Note that based on the packing density, the maximum fill level “H” may vary for each type of object and for each type of container.

In step 4504, a passing object directed to the container is detected using a sensor unit. Referring back to FIG. 25, the sensor unit 4202 may be configured to detect the waste tube 4206 falling into the container 4208. In one embodiment, the falling waste tube 4206 may be detected using a short range portion of the sensor unit 4202. In one embodiment, the falling waste tube 4206 may be detected using a short range ultrasonic sensor 4306 or an optical sensor 4402.

In step 4506, a waste counter value is incremented when the passing object is detected. For example, a waste counter may be initialized to zero in the memory 1110 of the processing unit 1106 to which the sensor unit 4202 may be communicatively coupled to. In some embodiments, if there are already objects in the container, the waste counter may be initialized to a value determined by the processor based on a fill level of the container, as discussed later. When the sensor unit 4202 detects the falling waste tube 4206, it generates an output that is transmitted to the processor 1108. The processor 1108 may communicate with the memory 1110 to increment the waste counter based on the output. The waste counter may represent a number of objects counted by the processor 1108. However, there may be possible errors made during counting, e.g., the passing object may be counted more than once or not counted at all.

In step 4508, a fill level H₁ of the container is measured using the sensor unit. Referring back to FIG. 25, in the absence of the waste tube 4206, the beam 4210 gets reflected downwards from the deflector surface 4204C of the bottom chute 4204 and further gets reflected from the surface of the waste tube 4206 deposited in the container 4208. Based on the amplitude of the reflected signal, the sensor unit 4202 may generate an output that is transmitted to the processor 1108. The processor 1108 may determine an estimate for a number of objects in the container 4208 using a measurement based on the output. For example, the processor 1108 may determine an estimate for the number of objects in the container for a given fill level by dividing a volume of the container for the given fill level (e.g., (H₁* cross sectional area of the container) by a volume of the object. Embodiments of the invention may provide an estimate of the fill level that may be in between zero and full, e.g., quarter full, forty percent full, half full, eighty percent full, etc. In one embodiment, the output may be generated by the long range sensor 4308.

In step 4510, a value for a number of objects in the container is determined by the processor based on the waste counter value and the estimate for the number of objects in the container. In one embodiment of the invention, as explained above, the waste counter value and the estimated number of objects are weighted using different weight factors that may change based on the fill level of the container.

As shown in FIG. 29A, a level 4604 represents maximum fill level “H” of a waste container such as the container 4208. A level 4606 represents a (partial) fill level “H₁” when a waste tube 4602 with at least one known geometric dimension is dropped in to the empty waste container. In one embodiment, based on the maximum fill level H, the fill level H₁ and the information that at least one waste tube 4602 with known geometric dimensions was dropped in the container, the number of waste tubes that may possibly additionally fit in the waste container can be calculated by the processor 1108.

In step 4512, the value for the number of objects in the container is corrected by the processor based on a weighted average. Different objects may have varying dimensions (e.g., a long side and a short side of the object). As a result of the varying dimensions, the fill level H₁ may differ significantly from an ideal level for an optimized packing density of the objects in the container. In one embodiment, for up to the maximum capacity or a part of the maximum capacity (e.g., 1/10^(th) of a maximum capacity) for a container, the value for the number of objects in the container may be further corrected as discussed below. In one embodiment, the corrected value may be used by the output robot 3402 (as shown in FIG. 23) to determine how may more waste tubes may be dropped (e.g., using the gripper unit 3002) into the container 3406. Calculating a more realistic fill level of the container may help to avoid surprises. For example, a waste container may be full due to irregular stacking, even though a waste counter may indicate that there is still space left in the container to hold more objects.

In one embodiment, the number of objects in the container may be represented as:

X(N _(count) *W _(count))+(N _(meas) *W _(meas))   Equation (1)

where,

N_(count)=number of counted objects,

W_(count)=a first weight factor for counted objects,

N_(meas)=number of objects estimated from measurement and

W_(meas)=a second weight factor for estimation from measurement.

In one embodiment, N_(count) is same as the waste counter that may be incremented by the processor 1108 based on the output from the sensor unit every time the presence of a passing object is detected by the sensor unit. N_(meas) may be calculated by the processor 1108 based on the output from the sensor unit after detecting a fill level H₁ of the container. For example, for a given fill level H₁, the N_(meas) may be determined by the processor 1108 using the following equation:

N _(meas)=(H ₁*cross sectional area (container))/volume of the object. Equation (2)

The first weight factor W_(count) and the second weight factor W_(meas) may be stored in the memory 1110 and can be pre-determined by the processor 1108 based on the geometric dimensions of the object and the container. In one embodiment, the first weight factor W_(count) and the second weight factor W_(meas) may be used as specified in Table 1 below:

Objects in the waste container W_(count) W_(meas)  0-10 1 0 11-20 0.75 0.25 21-30 0.5 0.5 31-40 0.25 0.75 41-50 0.1 0.9 51+ 0 1

After reaching a predetermined count (e.g., approximately 1/10^(th) of the given maximum capacity) for a container, the estimation will be more and more precise and may not need to be corrected any longer. As shown in the exemplary Table 1, when the number of objects in a container is more than 50, no weight is given to the number of counted objects (e.g., W_(count) is zero). The measured fill level becomes more accurate when more objects are present in the container.

As illustrated in FIG. 29B, as additional objects are dropped into the waste container, the fill level H₁ increases to a level 4608. As discussed above, the fill level measurement value may have more weight than the counted value, as the fill level measurement value may provide a more realistic estimate of the number of objects in the container.

A number of objects further fitting in the container may be determined by the processor. For example, a value for a number of the objects that will additionally fit in the waste container may be determined by the processor 1108 by subtracting the number of objects in the container (from equation 1) from a maximum number of objects that will fit in the container. In one embodiment, the maximum number of objects that will fit in the container may be determined by the processor 1108 by dividing a volume of the container with a volume of the object for a given packing density.

In step 4514, a number of objects further fitting in the container may be determined by the processor. For example, a value for a number of the objects that will additionally fit in the waste container may be determined by the processor 1108 by subtracting the number of objects in the container (from equation 1) from a maximum number of objects that will fit in the container. In one embodiment, the maximum number of objects that will fit in the container may be determined by the processor 1108 by dividing a volume of the container with a volume of the object for a given packing density.

In step 4516, it is determined if the fill level H₁ matches the maximum fill level H. If the fill level H₁ is less than the maximum fill level H, then additional passing objects may be detected as shown in step 4504 since the container is not yet full. As shown in FIG. 29C, if the fill level H₁ matches the maximum fill level H, the container may be full. In some embodiments, instead of the maximum fill level H, the fill level H₁ may be compared with a predetermined value to generate notification messages for different fill levels. Embodiments of the invention provide a more realistic estimate of the true fill level of the container so that an operator or a user can react in time and can schedule maintenance actions accordingly.

In step 4518, if the fill level H₁ matches the maximum fill level H, a notification message may be generated. For example, the notification message may include an alert message to empty the container or replace a full container with an empty container. However, in most cases, there may still be space in the waste container to the left and right of the highest fill level due to non-optimal deposit of the objects as they fall in the container. In one embodiment, the processor 1108 may compare the fill level H₁ with the predetermined maximum fill level H based on the output from the sensor unit and may generate the notification message. In one embodiment, the notification message is provided to the operator 1102 so that the container may be emptied or replaced with another empty container. In some cases, it may be desirable to have the container only partially full, e.g., eighty percent full or half full. In embodiments of the invention, a notification message may be generated for a partial fill level of the container. In some embodiments, it may be advantageous to have a notification for a partial fill level so that the upstream and downstream modules may adjust their processes knowing how many more waste objects can be filled in the container. In some embodiments, a programmable predetermined level may be stored in the memory 1110 for generating the notification message, e.g., half fill level or sixty percent fill level.

In one embodiment, handling of consumable objects (i.e., objects that are removed from a container to be consumed later) will follow a reverse method as compared to the one discussed for the disposable objects with reference to FIGS. 29A-29C. Handling of the consumable objects is further discussed with reference to FIG. 30 and FIGS. 31A-31C.

FIG. 30 illustrates a method 4700 for detecting the fill level of a container with consumable objects, in one embodiment.

In step 4702, a maximum fill level “H” of a container is determined. In the beginning, consumable objects may be filled in a container, e.g., a consumable container 4800, as shown in FIG. 31A, that may be part of the container unit 1128. In some embodiments, the consumable objects may be fed into the consumable container 4800 using the feeder unit 1130, such as a bowl feeder or a step feeder. In one embodiment, the consumable objects may be handled by an object handling unit that may be part of the laboratory automation system 1104.

As shown in FIG. 31A, a level detection sensor may be used to detect whether the consumable objects were filled in the consumable container 4800 up to a predetermined maximum level 4802 (e.g., H₁=H). In one embodiment, the level detection sensor may be part of the sensor unit 1120. For example, the ultrasonic sensor 4308 may be used to detect the measured fill level H₁, as discussed with reference to FIGS. 29A-29C. Alternatively, a light barrier located close to the top of the container (as shown in FIG. 31A) may be used to detect the level of the filled objects. If the desired maximum level is not reached, an alert message may be generated by the processing unit coupled to the appropriate sensor unit. For example, the alert message may be sent to the operator 1102 so that the operator 1102 may fill the consumable container to a defined or predetermined maximum level.

In step 4704, a consumable counter value is set to a defined maximum value for a given container and the object. In one embodiment, the maximum value of the consumable counter may be determined by the processing unit 1106 based on the known dimensions (e.g., width, height and length) of the consumable container and one or more geometric dimensions of the object, as discussed previously. For example, the maximum value may be determined by dividing a volume of the container by a volume of the object for a given packing density. In one embodiment, the consumable counter value may be stored in the memory 1110 and controlled by the processor 1108.

In step 4706, the counter value is decremented when a consumable object is removed from the container. In some embodiments, a gripper unit such as the gripper unit 3002 may be used to remove an object from the consumable container 4800 and transport it for further processing. For example, the gripper unit 3002 may be used to remove a cap from the container filled with caps to transport it to a storage unit to close a sample tube for storage or other purposes.

In step 4708, the fill level H₁ of the container is determined using a sensor unit. For example, the long range sensor 4308 may be used to detect the fill level of the consumable container. As shown in FIG. 31B, the (partial) fill level H₁ may be reduced to a level 4804 as objects are removed from the consumable container 4800.

In step 4710, a value for number of consumable objects remaining in the container is determined. In one embodiment, the value for the number of objects still remaining in the container may be determined based on the value of the consumable counter, and the fill level H₁ as measured by the sensor unit. However, due to errors in counting, the irregular geometry of the consumable objects and the varying packing density of the consumable objects in the container, the value may need to be corrected as fewer objects are remaining in the consumable container.

In step 4712, the value is corrected based on a weighted average using equation (1) as discussed previously. For example, more weight may be given to the measured fill level N_(meas) in the beginning (e.g., the container is almost full) when fewer objects are removed from the container, whereas, more weight may be given to the counter N_(count) towards the end when there are fewer objects left in the container (e.g., the container is almost empty). Note that since N_(count) is initialized to a maximum counter value and is decremented every time an object is removed, N_(count) in equation 1 represents the number of objects remaining in the container as counted by the processor.

In step 4714, it is determined if the fill level H₁ is zero. If the corrected estimated value for the remaining consumable objects in the container is zero, the container may be empty and may need to be refilled again. As shown in FIG. 31C, a level 4806 represents a zero fill level H₁.

In step 4716, if the fill level is zero, a notification message may be generated to refill the container. In one embodiment, the processor 1108 may compare the fill level H₁ to be zero based on the output from the sensor unit and generate the notification message. In one embodiment, the notification message is provided to the operator 1102 so that the container may be refilled or replaced with another full container. In one embodiment, a notification may be generated for a predetermined fill level of the container. In some embodiments, it may be advantageous to have a notification for a partial fill level so that the upstream and downstream modules may adjust their processes knowing how many more consumable objects are still remaining in the container. Thus, an operator or a user may align refill exchange of different consumables based on a realistic value of the objects left in the container. For example, a notification message may be generate when the container is almost empty (e.g., ninety five percent) instead of completely empty. Therefore, by receiving a notification message that a first consumable container may be getting empty soon, a second consumable container may be prepared without any downtime during the normal operation of the subsystem.

In one embodiment, a plurality of containers may be used, as discussed with reference to FIG. 13.

FIG. 32 illustrates an exemplary specimen output system 4900.

As illustrated in the figure, the deck 3308 may be coupled to an output frame 4906 with a plurality of containers 4904 located underneath the deck 3308. The plurality of containers 4904 may be part of the container unit 1128 as shown in FIG. 2. In one embodiment, discarded objects may be released in one of the containers 4904. Referring back to FIGS. 19 and 23, the output robot 3402 may grip an object using the gripper unit 3002 to drop objects in to one of the plurality of containers 4904. In another embodiment, the containers 4904 may be filled with consumable objects that can be removed by the output robot 3402 using the gripper unit 3002 and transported to another unit for further processing. A system 4902 may be configured to control the output robot 3402 to grip the objects for disposal or pick up the consumable objects from the containers 4904. In one embodiment, a sensor unit such as the sensor unit 1120 may be configured to detect the fill level of the containers 4904 in collaboration with the processing unit 1106 that may be part of the system 4902. As illustrated in the figure, one or more containers 4904 may be easily removed or replaced without affecting the whole arrangement.

FIG. 33 illustrates an arrangement 5000 for a bin frame 5006 with a door 5004.

A container 5002 may be positioned to collect an object dropped through the chute arrangement 3012, as shown in FIG. 19. The bottom part of the chute arrangement 3012 may be mounted on the deckbase 3310. The ultrasonic sensor 3018 may be configured to detect a passing object through the chute arrangement 3012 into the waste container 5002. The ultrasonic sensor 3018 may also be configured to detect the fill level of the container 5002. An output robot (e.g., the output robot 3402) may be configured to control a robotic gripper (i.e., gripper unit 3002) to grip an object (i.e., disposable specimen container) from an object handling unit and drop it though the chute arrangement 3012. Alternatively, an object may be removed from the container 5002 filled with the consumable objects. In some embodiments, after emptying the waste container or refilling the consumable container, the filling level may need to be reset, as discussed with reference to FIGS. 34 and 35.

In one embodiment, to reset the filling level after emptying the disposable objects from a waste container following steps may be performed, as discussed with reference to FIG. 34.

In step 5102, an operator removes the waste container to empty out the disposable or waste objects. Referring back to FIG. 33, the operator may request opening of the door 5004 to access the container 5002 to empty out the container. In one embodiment, the arrangement 5000 may be coupled to the system 4902 that operates as a controller. The system may notice the removal of the container 5002 or the opening of the door 5004. For example, opening of the door 5004 may be detected using a light barrier and/or a door status switch. The sub-system, e.g., the output robot 3402, may temporarily be set on hold so that the container 5002 is not accessed while the door 5004 is open and the container 5002 is removed.

In step 5104, the operator may insert a waste container. For example, the operator may insert the container 5002 back after emptying it out or insert another empty container (e.g., in the plurality of containers 4904 as shown in FIG. 32). In some embodiments, the operator may close the door 5004. Closing of the door may be detected by the system, e.g., using a light barrier.

In step 5106, a sensor unit such as the sensor unit 4202 detects a fill level H₁ as discussed previously with reference to FIGS. 28, 29A-29C.

In step 5108, the fill level H₁ is compared with the maximum fill level H to determine if the container 5002 is empty.

In step 5110, if the fill level H₁ is equal to the maximum fill level H, the waste counter is set to zero since the container 5002 is empty.

In step 5112, if the fill level H₁ is less than the maximum fill level H, the waste counter may be set to a value calculated using the latest average fill height of one piece of waste object, the latest waste counter, the latest fill level H₁, and the difference between H and H₁. In one embodiment, the latest waste counter and the latest fill level H₁ may be equal to the last value of the waste counter and H₁ stored in the memory 1110 before the container 5002 was removed. In some embodiments, the latest average fill height may represent an average of various fill heights of the waste object memorized by the system over the use of the system.

In step 5114, a status of the subsystem may be set to “functional” again so that the container 5002 may be filled with more waste objects.

In one embodiment, when two waste containers are used instead of a single waste container, one of the two waste container may be emptied without interrupting the work cycle of the system.

In one embodiment, to reset the filling level after refilling of the consumable objects into a container such as the container 5002, following steps are performed, as discussed with reference to FIG. 35.

To remove a consumable container for refilling by opening a door, steps 5102 and 5104 are followed, as discussed with reference to FIG. 34.

In step 5202, the operator fills in the consumable container with the standard bulk cargo, e.g., push caps, secondary test tubes, capillaries, etc. The operator may further insert the container 5002 and close the door 5004. The system notices the presence of the consumable container, for example, by detecting opening of the door 5004 using a light barrier. In one embodiment, the system may remember that the door was open before so closing the door may indicate presence of the container 500.

In step 5204, the system determines whether consumables were filled in the container 5002 by means of a level detection sensor. In one embodiment, an ultrasonic sensor may be used to detect the fill level H₁ as discussed with reference to FIG. 28. In another embodiment, a simple light barrier may be used to detect the level.

In step 5206, it is determined if the consumables were filled to a defined maximum level.

In step 5208, an alert message may be sent to the operator if the consumables were not filled to a desired maximum level.

In step 5210, a consumable counter may be set to a defined maximum value.

In step 5212, status of the subsystem is set to “functional” again so that the objects may be removed from the consumable container as discussed with reference to FIGS. 30, 31A-31C.

In one embodiment, when two consumable containers are used instead of a single consumable container, one of the two consumable containers may be refilled without interrupting the work cycle of the system.

As discussed above, embodiments of the invention provide different fill levels of objects in the container. A notification message may be sent to an operator for different fill levels so that an appropriate action may be taken. Further, by making use of more than one container, the containers may be replaced without interrupting the work cycle of the system.

A number of specific embodiments that can determine a fill level of objects in a container are described in this section. Embodiments of the invention may include various combinations of the features of such systems with features in the above-described systems that utilize a strip off element and corresponding chute arrangement, as well as systems that utilize the sensing gripper unit embodiments and/or replaceable gripper finger embodiments. For example, in some embodiment, the system comprises an element comprising a tubular body comprising a central axial bore running the length of said body with a first open end and a second open end, the first end including two or more slots parallel to the axis of the central axial bore. The system also comprises a container for holding objects passing through the tubular body, and a sensor unit configured to generate a first output by detecting a fill level of the container. The system further comprises a processor configured to determine different levels of the objects in the container as the objects fill the container or are removed from the container based on at least the first output. Other details regarding features of such combinations are provided above.

V. Computer Architecture

The various participants and elements described herein with reference to FIG. 2 may operate one or more computer apparatuses to facilitate the functions described herein. Any of the elements in the above description, including any servers, processors, or databases, may use any suitable number of subsystems to facilitate the functions described herein, such as, e.g., functions for operating and/or controlling the functional units and modules of the laboratory automation system, transportation systems, the scheduler, the central controller, local controllers, etc.

Examples of such subsystems or components are shown in FIG. 36. The subsystems shown in FIG. 36 are interconnected via a system bus 10. Additional subsystems such as a printer 18, keyboard 26, fixed disk 28 (or other memory comprising computer readable media), monitor 22, which is coupled to display adapter 20, and others are shown. Peripherals and input/output (I/O) devices, which couple to I/O controller 12 (which can be a processor or other suitable controller), can be connected to the computer system by any number of means known in the art, such as serial port 24. For example, serial port 24 or external interface 30 can be used to connect the computer apparatus to a wide area network such as the Internet, a mouse input device, or a scanner. The interconnection via system bus allows the central processor 16 to communicate with each subsystem and to control the execution of instructions from system memory 14 or the fixed disk 28, as well as the exchange of information between subsystems. The system memory 14 and/or the fixed disk 28 may embody a computer readable medium.

Embodiments of the technology are not limited to the above-described embodiments. Specific details regarding some of the above-described aspects are provided above. The specific details of the specific aspects may be combined in any suitable manner without departing from the spirit and scope of embodiments of the technology. For example, back end processing, data analysis, data collection, and other processes may all be combined in some embodiments of the technology. However, other embodiments of the technology may be directed to specific embodiments relating to each individual aspect, or specific combinations of these individual aspects.

It should be understood that the present technology as described above can be implemented in the form of control logic using computer software (stored in a tangible physical medium) in a modular or integrated manner. Furthermore, the present technology may be implemented in the form and/or combination of any image processing. Based on the disclosure and teachings provided herein, a person of ordinary skill in the art will know and appreciate other ways and/or methods to implement the present technology using hardware and a combination of hardware and software

Any of the software components or functions described in this application, may be implemented as software code to be executed by a processor using any suitable computer language such as, for example, Java, C++ or Perl using, for example, conventional or object-oriented techniques. The software code may be stored as a series of instructions, or commands on a computer readable medium, such as a random access memory (RAM), a read only memory (ROM), a magnetic medium such as a hard-drive or a floppy disk, or an optical medium such as a CD-ROM. Any such computer readable medium may reside on or within a single computational apparatus, and may be present on or within different computational apparatuses within a system or network.

The above description is illustrative and is not restrictive. Many variations of the technology will become apparent to those skilled in the art upon review of the disclosure. The scope of the technology should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the pending claims along with their full scope or equivalents.

One or more features from any embodiment may be combined with one or more features of any other embodiment without departing from the scope of the technology.

A recitation of “a”, “an” or “the” is intended to mean “one or more” unless specifically indicated to the contrary.

All patents, patent applications, publications, and descriptions mentioned above are herein incorporated by reference in their entirety for all purposes. None is admitted to be prior art. 

1. A system for use in manipulating a specimen container, the system comprising: a gripper unit for gripping the specimen container, the gripper unit comprising a mounting structure, a plurality of gripper fingers, a plurality of release elements respectively coupling the gripper fingers in the plurality of gripper fingers to the mounting structure, and a sensing device, wherein the sensing device is configured to produce an output; and a processor, wherein the processor is configured to determine a dimension or a weight of the specimen container based on the output.
 2. The system of claim 1, wherein the sensing device is a sensing potentiometer and the processor is configured to determine the dimension of the specimen container.
 3. The system of claim 1, wherein the sensing device is a load cell and the processor is configured to determine the weight of the specimen container.
 4. The system of claim 1, wherein the plurality of gripper fingers comprises a first gripper finger and a second gripper finger, and wherein the system further comprises: an optical sensor system including a light source communicatively coupled to the processor and a light receiver communicatively coupled to the processor, wherein the light source is coupled to the first gripper finger and the light receiver is coupled to the second gripper finger.
 5. The system of claim 4, wherein each release element comprises a plate and a first sliding element coupled to the plate, wherein the first sliding element is configured to pass through corresponding cavities in the mounting structure and a gripper finger in the plurality of gripper fingers.
 6. The system of claim 5, further comprising: a second sliding element coupled to the plate, wherein the second sliding element is configured to enable the first sliding element to release the first gripper finger when the second sliding element is pressed.
 7. The system of claim 4, wherein the release element comprises a first sliding element, and wherein the system further comprises: a lever coupled to the mounting structure, and wherein the first sliding element is configured to release the first gripper finger when the lever is rotated in a first direction.
 8. The system of any claim 1, wherein the system further comprises a robot arm coupled to the gripper unit.
 9. The system of claim 1, further comprising a chute arrangement below the gripper unit.
 10. The system of claim 9, further comprising a container positioned under the chute arrangement.
 11. The system of claim 1, further comprising at least one of a decapper, an aliquoter, and an analyzer.
 12. A system for manipulating objects, the system comprising: an element comprising a tubular body comprising a central axial bore running the length of said body with a first open end and a second open end, the first end including two or more slots parallel to the axis of the central axial bore; a container for holding objects passing through the tubular body; a sensor unit configured to generate a first output by detecting a fill level of the container, and a processor configured to determine different levels of the objects in the container as the objects fill the container or are removed from the container based on at least the first output.
 13. The system of claim 12, wherein the sensor unit is further configured to generate a second output by detecting the presence of an object passing into the container.
 14. The system of claim 12 or claim 13, wherein the objects are waste objects.
 15. The system of claim 12, wherein the processor is configured to determine a number of objects in the container based on a number of objects counted by the processor and a number of objects estimated by the processor using the first output.
 16. The system of claim 12, wherein the tubular body is part of a chute arrangement, wherein the chute arrangement further comprises an adapter unit coupled to the tubular body and a bottom chute coupled to the adapter unit.
 17. The system of claim 16 further comprising a platform, wherein the chute arrangement is mounted to the platform.
 18. The system of claim 12, wherein the tubular body has a square shaped profile.
 19. The system of any of claim 12, further comprising at least one of a decapper, an analyzer, and an aliquoter.
 20. The system of claim 12, further comprising a gripper unit comprising a plurality of gripper fingers, wherein the gripper unit is positioned above the tubular body.
 21. The system of claim 12, further comprising: a gripper unit comprising a mounting structure, a plurality of gripper fingers, and a plurality of release elements respectively coupling the gripper fingers in the plurality of gripper fingers to the mounting structure, and wherein the processor is configured to determine a dimension or a weight of the specimen container based on a second output from the sensor unit, and wherein the gripper unit is positioned above the element and the container.
 22. The system of claim 12 further comprising: a gripper unit comprising a mounting structure, a plurality of gripper fingers, and a plurality of release elements respectively coupling the gripper fingers in the plurality of gripper fingers to the mounting structure.
 23. The system of claim 12, further comprising: a gripper unit, wherein the processor is configured to determine a dimension or a weight of the specimen container based on a second output from the sensor unit, and wherein the gripper unit is positioned above the element and the container. 